Multi-axis pivot joints for surgical instruments and methods for manufacturing same

ABSTRACT

Multi-axis pivot joints and surgical instrument drive shafts formed using additive manufacturing methods.

BACKGROUND

The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments, end effectors, and staple cartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:

FIG. 1 is a perspective view of a surgical stapling instrument comprising a handle, a shaft assembly, and an end effector, in accordance with at least one aspect of the present disclosure.

FIG. 2 is a perspective view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1, wherein the end effector is illustrated in a straight, or non-articulated, configuration, in accordance with at least one aspect of the present disclosure.

FIG. 3 is a perspective view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1, wherein the end effector is illustrated in an articulated configuration, in accordance with at least one aspect of the present disclosure.

FIG. 4 is an exploded perspective view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1, in accordance with at least one aspect of the present disclosure.

FIG. 5 is a cross-sectional elevation view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1, wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 6 is a plan view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1, in accordance with at least one aspect of the present disclosure.

FIG. 7 is a cross-sectional elevation view of the end effector and a portion of the shaft assembly of FIG. 1 taken along section line 6-6 in FIG. 6, wherein the end effector is illustrated in an open configuration, in accordance with at least one aspect of the present disclosure.

FIG. 8 is a cross-sectional elevation view of the end effector and a portion of the shaft assembly of FIG. 1 taken along section line 7-7 in FIG. 6, wherein the end effector is illustrated in a clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 9 is a perspective view of a surgical stapling assembly comprising a shaft assembly and the end effector of FIG. 1, wherein the end effector is attached to the shaft assembly by way of an articulation joint, in accordance with at least one aspect of the present disclosure.

FIG. 10 is an exploded perspective view of the surgical stapling assembly of FIG. 9, in accordance with at least one aspect of the present disclosure.

FIG. 11 is a cross-sectional elevation view of the surgical stapling assembly of FIG. 9, wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 12 is a perspective view of a surgical stapling assembly comprising a shaft assembly and the end effector of FIG. 1, wherein the end effector is attached to the shaft assembly by way of an articulation joint, in accordance with at least one aspect of the present disclosure.

FIG. 13 is an exploded perspective view of the surgical stapling assembly of FIG. 12, in accordance with at least one aspect of the present disclosure.

FIG. 14 is a cross-sectional elevation view of the surgical stapling assembly of FIG. 12, wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 15 is a perspective view of a surgical stapling assembly comprising a shaft assembly and the end effector of FIG. 1, wherein the end effector is attached to the shaft assembly by way of an articulation joint, in accordance with at least one aspect of the present disclosure.

FIG. 16 is an exploded perspective view of the surgical stapling assembly of FIG. 15, in accordance with at least one aspect of the present disclosure.

FIG. 17 is a cross-sectional elevation view of the surgical stapling assembly of FIG. 15, wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 18 is a perspective view of a surgical end effector assembly comprising the end effector of FIG. 1 and a flexible firing drive system, in accordance with at least one aspect of the present disclosure.

FIG. 19 is an exploded perspective view of the surgical stapling assembly of FIG. 18, in accordance with at least one aspect of the present disclosure.

FIG. 20 is a cross-sectional elevation view of the surgical end effector assembly of FIG. 18, wherein the surgical end effector assembly is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 21 is a perspective view of robotic controller, in accordance with at least one aspect of the present disclosure.

FIG. 22 is a perspective view of a robotic arm cart for a robotic surgical system, depicting manipulators on the robotic arm cart operably supporting surgical tools, in accordance with at least one aspect of the present disclosure.

FIG. 23 is a side view of a manipulator of the surgical arm cart of FIG. 22 and a surgical grasping tool, in accordance with at least one aspect of the present disclosure.

FIG. 24 is a diagrammatical depiction of an example of an additive manufacturing system, in accordance with at least one aspect of the present disclosure.

FIG. 25 is a chart depicting one form of a manufacturing process that may be implemented by the additive manufacturing system of FIG. 24, in accordance with at least one aspect of the present disclosure.

FIG. 26 is a perspective view of one form of a universally movable joint that may be formed using the manufacturing process of FIG. 25 and the additive manufacturing system of FIG. 24, in accordance with at least one aspect of the present disclosure.

FIG. 27 is a cross-sectional view of the universally movable joint of FIG. 26, in accordance with at least one aspect of the present disclosure.

FIG. 28 is another perspective view of the universally movable joint of FIG. 26, in accordance with at least one aspect of the present disclosure.

FIG. 29 is a cross-sectional perspective view of the universally movable joint of FIG. 26, in accordance with at least one aspect of the present disclosure.

FIG. 30 is another cross-sectional view of the universally movable joint of FIG. 26 supported on a build plate of the additive manufacturing system of FIG. 24, in accordance with at least one aspect of the present disclosure.

FIG. 30A is another cross-sectional perspective view of the universally movable joint of FIG. 26 in green form, in accordance with at least one aspect of the present disclosure.

FIG. 30B is an enlarged view of a portion of a second cap and a bottom joint ring and a fillet space therebetween filled with an amount of build material in a first state during the formation of the green universally movable joint of FIG. 30, in accordance with at least one aspect of the present disclosure.

FIG. 30C is an enlarged view of a portion of a second cap and a portion of a joint spine of the green universally movable joint of FIG. 30 illustrating amounts of a build material in a first state located in a second horizontal joint space between the second cap and the joint spine, in accordance with at least one aspect of the present disclosure.

FIG. 31 is a cross-sectional view of another universally movable joint in green form supported on a build plate of the additive manufacturing system of FIG. 24 by multiple support members, in accordance with at least one aspect of the present disclosure.

FIG. 32 is a cross-sectional view of another universally movable joint in green formed supported on a build plate of the additive manufacturing system of FIG. 24, wherein a build material and a separate support material are employed during the manufacturing process, in accordance with at least one aspect of the present disclosure.

FIG. 33 is a cross-sectional view of another universally movable joint in green formed supported on a build plate of the additive manufacturing system of FIG. 24, wherein a joint spine is formed from a first build material and a vertical U-joint member and a horizontal U-joint member are formed from a second build material and a separate support material is employed during the manufacturing process, in accordance with at least one aspect of the present disclosure.

FIG. 34 is a perspective view of another universally movable joint embodiment, in accordance with at least one aspect of the present disclosure.

FIG. 35 is a cross-sectional view of the universally movable joint of FIG. 34, in accordance with at least one aspect of the present disclosure.

FIG. 36 is another cross-sectional view of the universally movable joint of FIG. 34, in accordance with at least one aspect of the present disclosure.

FIG. 37 is a perspective view of a universally movable drive shaft segment that comprises multiple universally movable joints that may be formed using the additive manufacturing system of FIG. 24 and/or the manufacturing process of FIG. 25, in accordance with at least one aspect of the present disclosure.

FIG. 38 is an exploded perspective assembly view of an articulation joint assembly embodiment that may be formed using the additive manufacturing system of FIG. 24 and/or the manufacturing process of FIG. 25, in accordance with at least one aspect of the present disclosure.

FIG. 39 is a perspective view of the articulation joint assembly of FIG. 38 showing a portion of a shaft assembly and a portion of an end effector in phantom lines, in accordance with at least one aspect of the present disclosure.

FIG. 40 is another perspective view of the articulation joint assembly of FIG. 38, in accordance with at least one aspect of the present disclosure.

FIG. 41 is a perspective assembly view of another articulation joint assembly embodiment that may be formed using the additive manufacturing system of FIG. 24 and/or the manufacturing process of FIG. 25, in accordance with at least one aspect of the present disclosure.

FIG. 42 is a perspective view of a mounting member embodiment and a universally movable joint embodiment, in accordance with at least one aspect of the present disclosure.

FIG. 43 is another perspective view of the mounting member and universally movable joint of FIG. 42 with a portion of a shaft, a conduit or a shaft guide extending through a center passage in the mounting member, in accordance with at least one aspect of the present disclosure.

FIG. 44 is a perspective view of a portion of an articulation joint embodiment coupling an end effector to a shaft assembly, in accordance with at least one aspect of the present disclosure.

FIG. 45 is a cross-sectional view of an intermediate closure drive shaft portion of the articulation joint of FIG. 44, in accordance with at least one aspect of the present disclosure.

FIG. 46 is a cross-sectional view of an intermediate firing drive shaft portion of the articulation joint of FIG. 44, in accordance with at least one aspect of the present disclosure.

FIG. 47 is a cross-sectional view of a portion of the end effector of FIG. 44 showing a coupling between a distal closure drive shaft and a closure screw and a coupling between a distal firing drive shaft and a firing screw, in accordance with at least one aspect of the present disclosure.

FIG. 48 is a cross-sectional end view of a closure coupler of FIG. 47 taken along section line 48-48 in FIG. 47, in accordance with at least one aspect of the present disclosure.

FIG. 49 is a cross-sectional view of a portion of another end effector showing a coupling between a distal closure drive shaft and a closure screw and a coupling between a distal firing drive shaft and a firing screw, in accordance with at least one aspect of the present disclosure.

FIG. 50 is a cross-sectional view of an articulation region of another surgical instrument, in accordance with at least one aspect of the present disclosure.

FIG. 51 is a perspective view of a portion of another surgical instrument, in accordance with at least one aspect of the present disclosure.

FIG. 52 is an exploded assembly view of a portion of the surgical instrument of FIG. 51, in accordance with at least one aspect of the present disclosure.

FIG. 53 is a cross-sectional view of a portion of the surgical instrument of FIG. 51, in accordance with at least one aspect of the present disclosure.

FIG. 54 is a perspective view of a shaft guide embodiment, in accordance with at least one aspect of the present disclosure.

FIG. 55 is a proximal end view of the shaft guide embodiment of FIG. 54, in accordance with at least one aspect of the present disclosure.

FIG. 56 is a distal end view of the shaft guide embodiment of FIG. 54, in accordance with at least one aspect of the present disclosure.

FIG. 57 is a side view of the shaft guide embodiment of FIG. 54, in accordance with at least one aspect of the present disclosure.

FIG. 58 is another side view of the shaft guide embodiment of FIG. 54, in accordance with at least one aspect of the present disclosure.

FIG. 59 is another view of the shaft guide embodiment of FIG. 54 in a flexed position, in accordance with at least one aspect of the present disclosure.

FIG. 60 is another view of the shaft guide embodiment of FIG. 54 in another flexed position, in accordance with at least one aspect of the present disclosure.

FIG. 61 is another view of the shaft guide embodiment of FIG. 54, in accordance with at least one aspect of the present disclosure.

FIG. 62 is a cross-sectional view of the shaft guide embodiment of FIG. 56 taken along section line 62-62 in FIG. 56, in accordance with at least one aspect of the present disclosure.

FIG. 63 is a perspective view of a portion of another surgical instrument, in accordance with at least one aspect of the present disclosure.

FIG. 64 is an exploded assembly view of a portion of the surgical instrument of FIG. 63, in accordance with at least one aspect of the present disclosure.

FIG. 65 is a side view of an articulation joint assembly of the surgical instrument of FIG. 63, in accordance with at least one aspect of the present disclosure.

FIG. 66 is another side view of the articulation joint assembly of the surgical instrument of FIG. 63, in accordance with at least one aspect of the present disclosure.

FIG. 67 is another view of the articulation joint assembly of the surgical instrument of FIG. 63 in articulated configuration, in accordance with at least one aspect of the present disclosure.

FIG. 68 is another view of the articulation joint assembly of the surgical instrument of FIG. 63 in another articulated configuration, in accordance with at least one aspect of the present disclosure.

FIG. 69 is a perspective view of the articulation joint assembly of FIG. 68 with two articulation link members removed for clarity, in accordance with at least one aspect of the present disclosure.

FIG. 70 is an end view of a portion of the articulation joint assembly of FIG. 69, in accordance with at least one aspect of the present disclosure.

FIG. 71 is a perspective view of a shaft guide of the articulation joint assembly of the surgical instrument of FIG. 63, in accordance with at least one aspect of the present disclosure.

FIG. 72 is a perspective view of the articulation joint assembly of the surgical instrument of FIG. 63, in accordance with at least one aspect of the present disclosure.

FIG. 73 is a cross-sectional view of the articulation joint assembly of the surgical instrument of FIG. 63, in accordance with at least one aspect of the present disclosure.

FIG. 74 is a partial perspective view of an articulation system, in accordance with at least one aspect of the present disclosure.

FIG. 75 is a top view of a portion of another end effector in an unarticulated position, in accordance with at least one aspect of the present disclosure.

FIG. 76 is another top view of the end effector of FIG. 75 in a fully articulated position, in accordance with at least one aspect of the present disclosure.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various embodiments of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. Patent Applications that were filed on even date herewith and which are each herein incorporated by reference in their respective entireties:

-   U.S. Patent Application entitled METHOD OF USING A POWERED STAPLING     DEVICE, Attorney Docket No. END9298USNP1/200859-1M; -   U.S. Patent Application entitled SURGICAL STAPLING ASSEMBLY     COMPRISING NONPLANAR STAPLES AND PLANAR STAPLES, Attorney Docket No.     END9298USNP2/200859-2; -   U.S. Patent Application entitled SURGICAL STAPLE CARTRIDGE     COMPRISING LONGITUDINAL SUPPORT BEAM, Attorney Docket No.     END9298USNP3/200859-3; -   U.S. Patent Application entitled ROTARY-DRIVEN SURGICAL STAPLING     ASSEMBLY COMPRISING ECCENTRICALLY DRIVEN FIRING MEMBER, Attorney     Docket No. END9298USNP4/200859-4; -   U.S. Patent Application entitled ROTARY-DRIVEN SURGICAL STAPLING     ASSEMBLY COMPRISING A FLOATABLE COMPONENT, Attorney Docket No.     END9298USNP5/200859-5; -   U.S. Patent Application entitled DRIVERS FOR FASTENER CARTRIDGE     ASSEMBLIES HAVING ROTARY DRIVE SCREWS, Attorney Docket No.     END9298USNP6/200859-6; -   U.S. Patent Application entitled MATING FEATURES BETWEEN DRIVERS AND     UNDERSIDE OF A CARTRIDGE DECK, attorney Docket No.     END9298USNP7/200859-7; -   U.S. Patent Application entitled LEVERAGING SURFACES FOR CARTRIDGE     INSTALLATION, Attorney Docket No. END9298USNP8/200859-8; -   U.S. Patent Application entitled FASTENER CARTRIDGE WITH     NON-REPEATING FASTENER ROWS, Attorney Docket No.     END9298USNP9/200859-9; -   U.S. Patent Application entitled FIRING MEMBERS HAVING FLEXIBLE     PORTIONS FOR ADAPTING TO A LOAD DURING A SURGICAL FIRING STROKE,     Attorney Docket No. END9298USN P10/200859-10; -   U.S. Patent Application entitled STAPLING ASSEMBLY COMPONENTS HAVING     METAL SUBSTRATES AND PLASTIC BODIES, Attorney Docket No.     END9298USNP11/200859-11; -   U.S. Patent Application entitled JOINT ARRANGEMENTS FOR MULTI-PLANAR     ALIGNMENT AND SUPPORT OF OPERATIONAL DRIVE SHAFTS IN ARTICULATABLE     SURGICAL INSTRUMENTS, Attorney Docket No. END9298USNP13/200859-13;     and -   U.S. Patent Application entitled SURGICAL INSTRUMENT ARTICULATION     JOINT ARRANGEMENTS COMPRISING MULTIPLE MOVING LINKAGE FEATURES,     Attorney Docket No. END9298USNP14/200859-14.

Applicant of the present application owns the following U.S. Patent Applications and U.S. Patents that were filed on Dec. 19, 2017 and which are each herein incorporated by reference in their respective entireties:

-   U.S. Pat. No. 10,835,330, entitled METHOD FOR DETERMINING THE     POSITION OF A ROTATABLE JAW OF A SURGICAL INSTRUMENT ATTACHMENT     ASSEMBLY; -   U.S. Pat. No. 10,716,565, entitled SURGICAL INSTRUMENTS WITH DUAL     ARTICULATION DRIVERS; -   U.S. patent application Ser. No. 15/847,325, entitled SURGICAL TOOLS     CONFIGURED FOR INTERCHANGEABLE USE WITH DIFFERENT CONTROLLER     INTERFACES, now U.S. Patent Application Publication No.     2019/0183491; -   U.S. Pat. No. 10,729,509, entitled SURGICAL INSTRUMENT COMPRISING     CLOSURE AND FIRING LOCKING MECHANISM; -   U.S. patent application Ser. No. 15/847,315, entitled ROBOTIC     ATTACHMENT COMPRISING EXTERIOR DRIVE ACTUATOR, now U.S. Patent     Application Publication No. 2019/0183594; and -   U.S. Design Pat. No. D910,847, entitled SURGICAL INSTRUMENT     ASSEMBLY.

Applicant of the present application owns the following U.S. Patent Applications and U.S. Patents that were filed on Jun. 28, 2017 and which are each herein incorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 15/635,693, entitled SURGICAL     INSTRUMENT COMPRISING AN OFFSET ARTICULATION JOINT, now U.S. Patent     Application Publication No. 2019/0000466; -   U.S. patent application Ser. No. 15/635,729, entitled SURGICAL     INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO, now U.S. Patent     Application Publication No. 2019/0000467; -   U.S. patent application Ser. No. 15/635,785, entitled SURGICAL     INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO, now U.S. Patent     Application Publication No. 2019/0000469; -   U.S. patent application Ser. No. 15/635,808, entitled SURGICAL     INSTRUMENT COMPRISING FIRING MEMBER SUPPORTS, now U.S. Patent     Application Publication No. 2019/0000471; -   U.S. patent application Ser. No. 15/635,837, entitled SURGICAL     INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLE TO A FRAME,     now U.S. Patent Application Publication No. 2019/0000472; -   U.S. Pat. No. 10,779,824, entitled SURGICAL INSTRUMENT COMPRISING AN     ARTICULATION SYSTEM LOCKABLE BY A CLOSURE SYSTEM; -   U.S. patent application Ser. No. 15/636,029, entitled SURGICAL     INSTRUMENT COMPRISING A SHAFT INCLUDING A HOUSING ARRANGEMENT, now     U.S. Patent Application Publication No. 2019/0000477; -   U.S. patent application Ser. No. 15/635,958, entitled SURGICAL     INSTRUMENT COMPRISING SELECTIVELY ACTUATABLE ROTATABLE COUPLERS, now     U.S. Patent Application Publication No. 2019/0000474; -   U.S. patent application Ser. No. 15/635,981, entitled SURGICAL     STAPLING INSTRUMENTS COMPRISING SHORTENED STAPLE CARTRIDGE NOSES,     now U.S. Patent Application Publication No. 2019/0000475; -   U.S. patent application Ser. No. 15/636,009, entitled SURGICAL     INSTRUMENT COMPRISING A SHAFT INCLUDING A CLOSURE TUBE PROFILE, now     U.S. Patent Application Publication No. 2019/0000476; -   U.S. Pat. No. 10,765,427, entitled METHOD FOR ARTICULATING A     SURGICAL INSTRUMENT; -   U.S. patent application Ser. No. 15/635,530, entitled SURGICAL     INSTRUMENTS WITH ARTICULATABLE END EFFECTOR WITH AXIALLY SHORTENED     ARTICULATION JOINT CONFIGURATIONS, now U.S. Patent Application     Publication No. 2019/0000457; -   U.S. Pat. No. 10,588,633, entitled SURGICAL INSTRUMENTS WITH OPEN     AND CLOSABLE JAWS AND AXIALLY MOVABLE FIRING MEMBER THAT IS     INITIALLY PARKED IN CLOSE PROXIMITY TO THE JAWS PRIOR TO FIRING; -   U.S. patent application Ser. No. 15/635,559, entitled SURGICAL     INSTRUMENTS WITH JAWS CONSTRAINED TO PIVOT ABOUT AN AXIS UPON     CONTACT WITH A CLOSURE MEMBER THAT IS PARKED IN CLOSE PROXIMITY TO     THE PIVOT AXIS, now U.S. Patent Application Publication No.     2019/0000459; -   U.S. Pat. No. 10,786,253, entitled SURGICAL END EFFECTORS WITH     IMPROVED JAW APERTURE ARRANGEMENTS; -   U.S. patent application Ser. No. 15/635,594, entitled SURGICAL     CUTTING AND FASTENING DEVICES WITH PIVOTABLE ANVIL WITH A TISSUE     LOCATING ARRANGEMENT IN CLOSE PROXIMITY TO AN ANVIL PIVOT AXIS, now     U.S. Patent Application Publication No. 2019/0000461; -   U.S. patent application Ser. No. 15/635,612, entitled JAW RETAINER     ARRANGEMENT FOR RETAINING A PIVOTABLE SURGICAL INSTRUMENT JAW IN     PIVOTABLE RETAINING ENGAGEMENT WITH A SECOND SURGICAL INSTRUMENT     JAW, now U.S. Patent Application Publication No. 2019/0000462; -   U.S. Pat. No. 10,758,232, entitled SURGICAL INSTRUMENT WITH POSITIVE     JAW OPENING FEATURES; -   U.S. Pat. No. 10,639,037, entitled SURGICAL INSTRUMENT WITH AXIALLY     MOVABLE CLOSURE MEMBER; -   U.S. Pat. No. 10,695,057, entitled SURGICAL INSTRUMENT LOCKOUT     ARRANGEMENT; -   U.S. Design Pat. No. D851,762, entitled ANVIL; -   U.S. Design Pat. No. D854,151, entitled SURGICAL INSTRUMENT SHAFT;     and -   U.S. Design Pat. No. D869,655, entitled SURGICAL FASTENER CARTRIDGE.

Applicant of the present application owns the following U.S. Patent Applications and U.S. Patents that were filed on Jun. 27, 2017 and which are each herein incorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 15/634,024, entitled SURGICAL ANVIL     MANUFACTURING METHODS, now U.S. Patent Application Publication No.     2018/0368839; -   U.S. Pat. No. 10,772,629, entitled SURGICAL ANVIL ARRANGEMENTS; U.S.     patent application Ser. No. 15/634,046, entitled SURGICAL ANVIL     ARRANGEMENTS, now U.S. Patent Application Publication No.     2018/0368841; -   U.S. Pat. No. 10,856,869, entitled SURGICAL ANVIL ARRANGEMENTS; -   U.S. patent application Ser. No. 15/634,068, entitled SURGICAL     FIRING MEMBER ARRANGEMENTS, now U.S. Patent Application Publication     No. 2018/0368843; -   U.S. patent application Ser. No. 15/634,076, entitled STAPLE FORMING     POCKET ARRANGEMENTS, now U.S. Patent Application Publication No.     2018/0368844; -   U.S. patent application Ser. No. 15/634,090, entitled STAPLE FORMING     POCKET ARRANGEMENTS, now U.S. Patent Application Publication No.     2018/0368845; -   U.S. patent application Ser. No. 15/634,099, entitled SURGICAL END     EFFECTORS AND ANVILS, now U.S. Patent Application Publication No.     2018/0368846; and -   U.S. Pat. No. 10,631,859, entitled ARTICULATION SYSTEMS FOR SURGICAL     INSTRUMENTS.

Applicant of the present application owns the following U.S. Patent Applications that were filed on Jun. 2, 2020 and which are each herein incorporated by reference in their respective entireties:

-   U.S. Design patent application Ser. No. 29/736,648, entitled STAPLE     CARTRIDGE; -   U.S. Design patent application Ser. No. 29/736,649, entitled STAPLE     CARTRIDGE; -   U.S. Design patent application Ser. No. 29/736,651, entitled STAPLE     CARTRIDGE; -   U.S. Design patent application Ser. No. 29/736,652, entitled STAPLE     CARTRIDGE; -   U.S. Design patent application Ser. No. 29/736,653, entitled STAPLE     CARTRIDGE; -   U.S. Design patent application Ser. No. 29/736,654, entitled STAPLE     CARTRIDGE; and -   U.S. Design patent application Ser. No. 29/736,655, entitled STAPLE     CARTRIDGE.

Applicant of the present application owns the following U.S. Design Patent Applications and U.S. Patents that were filed on Nov. 14, 2016, and which are each herein incorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 15/350,621, now U.S. Patent     Application Publication No. 2018/0132849, entitled STAPLE FORMING     POCKET CONFIGURATIONS FOR CIRCULAR STAPLER ANVIL; -   U.S. patent application Ser. No. 15/350,624, now U.S. Patent     Application Publication No. 2018/0132854, entitled CIRCULAR SURGICAL     STAPLER WITH ANGULARLY ASYMMETRIC DECK FEATURES; -   U.S. Design Pat. No. D833,608, titled STAPLING HEAD FEATURE FOR     SURGICAL STAPLER; and -   U.S. Design Pat. No. D830,550, titled SURGICAL STAPLER.

Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a surgical system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

The terms “proximal” and “distal” are used herein with reference to a clinician manipulating the handle portion of the surgical device. The term “proximal” refers to the portion closest to the clinician and the term “distal” refers to the portion located away from the clinician. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings. However, surgical device are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute. In the following description, terms such as “first,” “second,” “top,” “bottom,” “up,” “down,” and the like are words of convenience and are not to be construed as limiting terms.

References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term “or” should generally be understood to mean “and/or”, etc.

Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the disclosure as if it were individually recited herein. The words “about,” “approximately” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Similarly, words of approximation such as “approximately” or “substantially” when used in reference to physical characteristics, should be construed to contemplate a range of deviations that would be appreciated by one of ordinary skill in the art to operate satisfactorily for a corresponding use, function, purpose or the like.

The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the embodiments. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the embodiments.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein can be used in numerous surgical procedures and applications including, for example, in connection with open surgical procedures. As the present Detailed Description proceeds, the reader will further appreciate that the various surgical devices disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc. The working portions or end effector portions of the surgical devices can be inserted directly into a patient's body or can be inserted through an access device that has a working channel through which the end effector and elongate shaft of a surgical device can be advanced.

A surgical stapling system can comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are envisioned in which a staple cartridge is not removable from, or at least readily replaceable from, the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to permit the end effector to be rotated, or articulated, relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of the tissue to be stapled and the anvil is positioned on a second side of the tissue to be stapled. The anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck. Thereafter, staples removably stored in the cartridge body can be deployed into the tissue. The cartridge body includes staple cavities defined therein wherein staples are removably stored in the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples are contemplated.

The staples are supported by staple drivers in the cartridge body. The drivers are movable between a first, or unfired, position and a second, or fired, position to eject the staples from the staple cavities. The drivers are retained in the cartridge body by a retainer which extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body. The drivers are movable between their unfired positions and their fired positions by a sled. The sled is movable between a proximal position adjacent a proximal end of the cartridge body and a distal position adjacent a distal end of the cartridge body. The sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. The firing member is configured to contact the sled and push the sled toward the distal end. The longitudinal slot defined in the cartridge body is configured to receive the firing member. The anvil also includes a slot configured to receive the firing member. The firing member further comprises a first cam which engages the first jaw and a second cam which engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck of the staple cartridge and the anvil. The firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramped surfaces such that the staples are ejected into the tissue ahead of the knife transecting the tissue.

FIGS. 1-8 depict a surgical stapling instrument 10 configured to clamp, staple, and cut tissue of a patient. The surgical stapling instrument 10 comprises a handle 20, a shaft assembly 100 attached to the handle 20, and an end effector 200. To cut and staple tissue of a patient, the end effector 200 comprises a cartridge jaw 201 and an anvil jaw 203. The anvil jaw 203 is pivotable relative to the cartridge jaw 203 to clamp tissue between the anvil jaw 203 and the cartridge jaw 203. Once tissue is clamped between the jaws 201, 203, the surgical stapling instrument 10 may be actuated to advance a firing member through the jaws 201, 203 to staple and cut tissue with the end effector 200 as discussed in greater detail below.

Discussed in greater detail below, the end effector 200 is articulatable by way of an articulation region 110 of the shaft assembly 100. Such articulation provides a user of the surgical stapling instrument 10 with the ability to position and/or maneuver the end effector 200 near the target tissue more accurately.

The handle 20 comprises a housing 21 configured to house various mechanical and electrical components and a handle portion 22 extending from the housing 21. The handle portion 22 is configured to fit in the palm of a user and/or be gripped and/or held by a user using the surgical stapling instrument 10. The handle 20 further comprises various actuators and/or triggers configured to be actuated by a user to operate one or more functions of the surgical stapling instrument 10. The handle 20 comprises a closure trigger 24, a firing trigger 25, and at least one articulation actuator 26. When actuated by a user, the closure trigger 24 is configured to clamp tissue with the end effector 200 by moving the anvil jaw 203 toward the cartridge jaw 201. When actuated by a user, the firing trigger 25 is configured to cut and staple tissue with the end effector 200 by advancing a firing member to eject staples and cut tissue with a knife. When actuated by a user, the articulation actuator 26 is configured to articulate the end effector 200 relative to the shaft assembly 100 by way of the articulation region 110. The triggers and actuators of the surgical stapling instrument 10 can either trigger one or more motors within the handle 20 to actuate various function of the surgical stapling instrument 10 and/or manually drive various drive shafts and components to actuate various function of the surgical stapling instrument 10.

The handle 20 further comprises a nozzle assembly 30 configured to support the shaft assembly 100 therein. The nozzle assembly 30 comprises an actuation wheel 31 configured to be rotated by a user to rotate the shaft assembly 100 and end effector 200 about a longitudinal axis LA relative to the handle 20. Such a mechanism permits the user of the surgical stapling instrument 10 to rotate only the shaft assembly 100 and/or end effector 200 without having to rotate the entire handle 20.

The handle 20 further comprises a battery 23 configured to provide power to various electronic components, sensors, and/or motors of the surgical stapling instrument 10. Embodiments are envisioned where the surgical stapling instrument 10 is directly connected to a power source. Embodiments are also envisioned where the surgical stapling instrument 10 is entirely manual or, non-powered, for example. Embodiments are further envisioned where articulation of the end effector, clamping and unclamping of the jaws, firing of the end effector staple and cut tissue, and shaft and/or end effector rotation are all powered systems.

In at least one instance, the shaft assembly 100 and the end effector 200 may be modular and removable from the handle 20. In at least one instance, the end effector 200 may be modular in that the end effector 200 can be removed from the shaft assembly 100 and replaced with a different end effector. In at least one instance, the shaft assembly 100 and/or the end effector 200 is employable in a surgical robotic environment. Such an embodiment would provide powered inputs from a surgical robotic interface to actuate each function of the end effector 200. Examples of such surgical robots and surgical tools are further described in U.S. Patent Application Publication No. 2020/0138534, titled ROBOTIC SURGICAL SYSTEM, which published on May 7, 2020, which is incorporated by reference herein in its entirety.

In at least one instance, the shaft assembly 100 and the end effector 200 are configured to be used with a surgical robot. In such an instance, the shaft assembly 100 and the end effector 200 are configured to be coupled to a surgical robot comprising a plurality of output drives. The plurality of output drives of the surgical robot are configured to mate with the drive systems of the shaft assembly 100 and end effector 200. In such an instance, the surgical robot can actuate the various different functions of the end effector 200 such as, for example, articulating the end effector about multiple different articulation joints, rotating the shaft assembly 100 and/or end effector 200 about its longitudinal axis, clamping the end effector 200 to clamp tissue between the jaws of the end effector 200, and/or firing the end effector 200 to cut and/or staple tissue.

The shaft assembly 100 is configured to house various drive system components and/or electronic components of the surgical stapling instrument 10 so that the end effector 200 and shaft assembly 100 may be inserted through a trocar for laparoscopic surgery. The various drive system components are configured to be actuated by the various triggers and actuators of the handle 20. Such components can include drive shafts for articulation, drive shafts for clamping and unclamping the end effector 200, and/or drive shafts for firing the end effector 200. Such drive shafts may be rotated by a drive system in the handle 20 or a surgical robotic interface in the instance where the shaft assembly 100 is connected to the same. In various aspects, a stapling end effector can include two independently rotatable drive members—one for grasping tissue and one for firing staples, for example. The stapling end effector can further include an articulation joint, and the rotary motions can be transmitted through the articulation joint. In various aspects, the stapling end effector can include one or more 3D printed assemblies, which can be incorporated into an articulation, grasping, or firing systems.

Such drive shafts may be actuated by a drive system in the handle 20 or a surgical robotic interface in the instance where the shaft assembly 100 is connected to the same. Such drive shafts may comprise linear actuation, rotary actuation, or a combination thereof. A combination of rotary actuation and linear actuation may employ a series of rack gears and/or drive screws, for example.

In at least one instance, the shaft assembly 100 is also configured to house electrical leads for various sensors and/or motors, for example, positioned within the shaft assembly 100 and/or end effector 200, for example.

The shaft assembly 100 comprises an outer shaft 101 extending from the nozzle assembly 30 to the articulation region 110 comprising dual articulation joints, discussed in greater detail below. The articulation region 110 allows the end effector 200 to be articulated relative to the outer shaft 101 in two distinct planes about two separate axes AA1, AA2.

Referring now primarily to FIG. 4, articulation of the end effector 200 will now be described. The articulation region 110 comprises two distinct articulation joints and two articulation actuators 150, 160. This allows the end effector 200 to be articulated in two different planes about two different axes AA1, AA2 independently of each other. The articulation region 110 comprises a proximal joint shaft component 120, an intermediate joint shaft component 130, and a distal joint shaft component 140. The proximal joint shaft component 120 is attached to a distal end of the shaft assembly 100, the intermediate joint shaft component 130 is pivotally connected to the proximal joint shaft component 120 and the distal joint shaft component 140, and the distal joint shaft component 140 is fixedly attached to the end effector 200 by way of a retention ring 146. Discussed in greater detail below, this arrangement provides articulation of the end effector 200 relative to the shaft assembly 100 about axis AA1 and axis AA2 independently of each other.

The proximal joint shaft component 120 comprises a proximal annular portion 121 fixedly fitted within the outer shaft 101. The proximal joint shaft component 120 also includes a hollow passage 122 to allow various drive system components to pass therethrough, and further includes an articulation tab 123 comprising a pin hole 124 configured to receive articulation pin 125. The articulation pin 125 pivotally connects the proximal joint shaft component 120 to a proximal articulation tab 131 of the intermediate joint shaft component 130. To articulate the end effector 200 about axis AA1, the articulation actuator 150 is actuated linearly either in a distal direction or a proximal direction. Such an actuator may comprise a bar or rod made of any suitable material such as metal and/or plastic, for example. The articulation actuator 150 is pivotally mounted to an articulation crosslink 151. The articulation crosslink 151 is pivotally mounted to the intermediate joint shaft component 130 off-axis relative to the articulation pin 125 so that when the articulation actuator 150 is actuated, a torque is applied to the intermediate joint shaft component 130 off-axis relative to the articulation pin 125 by the articulation crosslink 151 to cause the intermediate joint shaft component 130 and, thus, the end effector 200, to pivot about axis AA1 relative to the proximal joint shaft component 120.

The intermediate joint shaft component 130 is pivotally connected to the proximal joint shaft component 120 by way of the articulation pin 125 which defines axis AA1. Specifically, the intermediate joint shaft component 130 comprises a proximal articulation tab 131 that is pivotally connected to the proximal joint shaft component 120 by way of the articulation pin 125. The intermediate joint shaft component 130 further comprises a hollow passage 132 configured to allow various drive system components to pass therethrough and a distal articulation tab 133. The distal articulation tab 133 comprises a pin hole 134 configured to receive another articulation pin 136, which defines axis AA2, and a distally-protruding key 135.

To articulate the end effector 200 about axis AA2, the articulation cable 160 is actuated to apply an articulation torque to a proximal tab 141 of the distal joint shaft component 140 by way of the key 135. The articulation cable 160 is fixed to the key 135 such that, as the cable 160 is rotated, the key 135 is pivoted relative to the intermediate joint shaft component 130. The key 135 is fitted within a key hole 144 of the distal joint shaft component 140. Notably, the key 135 is not fixed to the intermediate joint shaft component 130 and the key 135 can be rotated relative to the intermediate joint shaft component 130. The articulation cable 160 also contacts the proximal tab 141 around the pin hole 142. This provides an additional torque moment from the articulation cable 160 to the distal joint shaft component 140. The articulation pin 136 is received within the pin hole 142 to pivotally couple the intermediate joint shaft component 130 and the distal joint shaft component 140.

In at least one instance, the articulation cable 160 is only able to be pulled in a proximal direction. In such an instance, only one side of the articulation cable 160 would be pulled proximally to articulate the end effector 200 in the desired direction. In at least one instance, the articulation cable 160 is pushed and pulled antagonistically. In other words, the cable 160 can comprise a rigid construction such that one side of the articulation cable 160 is pushed distally while the other side of the articulation cable 160 is pulled proximally. Such an arrangement can allow the articulation forces to be divided between the pushed half of the cable 160 and the pulled half of the cable 160. In at least one instance, the push-pull arrangement allows greater articulation forces to be transmitted to the corresponding articulation joint. Such forces may be necessary in an arrangement with two articulation joints. For example, if the proximal articulation joint is fully articulated, more force may be required of the articulation actuator meant to articulate the distal articulation joint owing to the stretching and/or lengthened distance that the articulation actuator for the distal articulation joint must travel.

The distal joint shaft component 140 further comprises a cutout 143 to allow various drive components to pass therethrough. The retention ring 146 secures a channel 210 of the cartridge jaw 201 to the distal joint shaft component 140 thereby fixing the end effector assembly 200 to a distal end of the articulation region 110.

As discussed above, the anvil jaw 201 is movable relative to the cartridge jaw 203 to clamp and unclamp tissue with the end effector 200. Operation of this function of the end effector 200 will now be described. The cartridge jaw 201 comprises the channel 210 and a staple cartridge 220 configured to be received within a cavity 214 of the channel 210. The channel 210 further comprises an annular groove 211 configured to receive the retention ring 146 and a pair of pivot holes 213 configured to receive a jaw-coupling pin 233. The jaw coupling pin 233 permits the anvil jaw 203 to be pivoted relative to the cartridge jaw 201.

The anvil jaw 203 comprises an anvil body 230 and a pair of pivot holes 231. The pivot holes 231 in the proximal portion of the anvil jaw 203 are configured to receive the jaw-coupling pin 233 thereby pivotally coupling the anvil jaw 203 to the cartridge jaw 201. To open and close the anvil jaw 203 relative to the cartridge jaw 201, a closure drive 250 is provided.

The closure drive 250 is actuated by a flexible drive segment 175 comprised of universally-movable joints arranged or formed end-to-end. In various instances, the flexible drive segment 175 can includes serial 3D-printed universal joints, which are printed all together as a single continuous system. Discussed in greater detail below, the flexible drive segment 175 is driven by an input shaft traversing through the shaft assembly 100. The flexible drive segment 175 transmits rotary actuation motions through the dual articulation joints. The closure drive 250 comprises a closure screw 251 and a closure wedge 255 threadably coupled to the closure screw 251. The closure wedge 255 is configured to positively cam the anvil jaw 203 open and closed. The closure screw 251 is supported by a first support body 258 and a second support body 259 secured within the channel 210.

To move the anvil jaw 203 between a clamped position (FIG. 8) and an unclamped position (FIG. 7), a closure drive shaft is actuated to actuate the flexible drive segment 175. The flexible drive segment 175 is configured to rotate the closure screw 251, which displaces the closure wedge 255. For example, the closure wedge 255 is threadably coupled to the closure screw 251 and rotational travel of the closure wedge 255 with the staple cartridge 220 is restrained. The closure screw 251 drives the closure wedge 255 proximally or distally depending on which direction the closure screw 251 is rotated.

To clamp the end effector 200 from an unclamped position (FIG. 7), the closure wedge 255 is moved proximally. As the closure wedge 255 is moved proximally, a proximal cam surface 256 of the closure wedge 255 contacts a corresponding cam surface 234 defined in a proximal end 235 of the anvil body 230. As the cam surface 256 contacts the cam surface 234, a force is applied to the proximal end 235 of the anvil body 230 causing the anvil body 230 to rotate into the clamped position (FIG. 8) about the pin 233.

To open or unclamp the end effector 200 from a clamped position (FIG. 8), the closure wedge 255 is moved distally by rotating the closure screw 251 in a direction opposite to the direction that causes the closure wedge 255 to move proximally. As the closure wedge 255 is moved distally, a pair of nubs 257 extending from a distal end of the closure wedge 255 contact the cam surface 234 near a downwardly extending tab 237 of the anvil body 230. As the nubs 257 contact the cam surface 234 near the tab 237, a force is applied to the anvil body 230 to rotate the anvil body 230 into the open position (FIG. 7) about the pin 233.

In at least one instance, the profile of the cam surface 234 corresponds to the profile of the cam surface 256. For example, the cam surface 234 and the cam surface 256 may match such that a maximum cam force is applied to the anvil body 230 to cause the desired rotation of the anvil body 230. As can be seen in FIG. 8, for example, the cam surface 234 defined by the proximal end 235 of the anvil body 230 comprises a ramped section similar to that of the upper ramped section of the cam surface 256.

As discussed above, the surgical stapling instrument 10 may be actuated to advance a firing member through the jaws 201, 203 to staple and cut tissue with the end effector 200. The function of deploying staples 226 from the staple cartridge 220 and cutting tissue with knife 283 will now be described. The staple cartridge 220 comprises a cartridge body 221, a plurality of staple drivers 225, and a plurality of staples 226 removably stored within the cartridge body 221. The cartridge body 221 comprises a deck surface 222, a plurality of staple cavities 223 arranged in longitudinal rows defined in the cartridge body 221, and a longitudinal slot 224 bifurcating the cartridge body 221. The knife 283 is configured to be driven through the longitudinal slot 224 to cut tissue clamped between the anvil body 230 and the deck surface 221.

The deck surface 221 comprises a laterally-contoured tissue-supporting surface. In various aspects, the contour of the deck surface 221 can form a peak along a central portion of the cartridge body 221. Such a peak can overlay a longitudinally-extending firing screw 261 that extends through the central portion of the cartridge body 221, which is further described herein. The increased height along the peak can be associated with a smaller tissue gap along a firing path of the knife 283 in various instances. In certain aspects of the present disclosure, driver heights, formed staple heights, staple pocket extension heights, and/or staple overdrive distances can also vary laterally along the deck surface 221. Laterally-variable staple formation (e.g. a combination of 2D staples and 3D staples) is also contemplated and further described herein.

The staple drivers 225 are configured to be lifted by a sled 280 as the sled 280 is pushed distally through the staple cartridge 220 to eject the staples 226 supported by the staple drivers 225 in the staple cavities 223. The sled 280 comprises ramps 281 to contact the staple drivers 225. The sled 280 also includes the knife 283. The sled 280 is configured to be pushed by a firing member 270.

To deploy the staples 226 and cut tissue with the knife 283, the end effector 200 comprises a firing drive 260. The firing drive 260 is actuated by a flexible drive shaft 176. Discussed in greater detail below, the flexible drive shaft 176 is driven by an input shaft traversing through the shaft assembly 100. The flexible drive shaft 176 transmits rotary actuation motions through the dual articulation joints. The firing drive 260 comprises a firing screw 261 configured to be rotated by the flexible drive shaft 176. The firing screw 261 comprises journals supported within bearings in the support member 259 and the channel 210. In various instances, the firing screw 261 can float relative to the channel 210, as further described herein. The firing screw 261 comprises a proximal end 262 supported within the support member 259 and the channel 210, a distal end 263 supported within the channel 210, and threads 265 extending along a portion of the length of the firing screw 261.

The firing member 270 is threadably coupled to the firing screw 261 such that as the firing screw 261 is rotated, the firing member 270 is advanced distally or retracted proximally along the firing screw 261. Specifically, the firing member 270 comprises a body portion 271 comprising a hollow passage 272 defined therein. The firing screw 261 is configured to be received within the hollow passage 272 and is configured to be threadably coupled with a threaded component 273 of the firing member 270. Thus, as the firing screw 261 is rotated, the threaded component 273 applies a linear force to the body portion 271 to advance the firing member 270 distally or retract the firing member 270 proximally. As the firing member 270 is advanced distally, the firing member 270 pushes the sled 280. Distal movement of the sled 280 causes the ejection of the staples 223 by engaging the plurality of staple drivers 225, as further described herein. The driver 225 is a triple driver, which is configured to simultaneously fire multiple staples 223. The driver 225 can comprise lateral asymmetries, as further described herein, to maximum the width of the sled rails and accommodate the firing screw 261 down the center of the cartridge 220 in various instances.

At a point during firing of the end effector 200, a user may retract the firing member 270 to allow unclamping of the jaws 201, 203. In at least one instance, the full retraction of the firing member 270 is required to open the jaws 201, 203 where upper and lower camming members are provided on the body portion 271 which can only be disengaged from the jaws 201, 203 once the firing member 270 is fully retracted.

In various instances, the firing member 270 can be a hybrid construction of plastic and metal portions as further described herein. In various instances, the threaded component 273 can be a metal component, for example, which is incorporated into the firing member body 271 with insert molding or over molding.

The firing member 270 can also be referred to an I-beam in certain instances. The firing member 270 can include a complex 3D-printed geometry comprising a lattice pattern of spaces therein. In various instances, 3D printing can allow the firing member or a portion thereof to act as a spring and allows a portion to more readily flex, which can improve the force distribution and/or tolerances during a firing stroke, for example.

FIGS. 9-11 depict a surgical stapling assembly 300 comprising a shaft assembly 310 and the end effector 200 of FIGS. 1-8 attached to the shaft assembly 310. The shaft assembly 310 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 310 comprises a single articulation joint and an articulation bar configured to articulate the end effector 200 about the single articulation joint. The surgical stapling assembly 300 is configured to cut and staple tissue. The surgical stapling assembly 300 may be attached to a surgical instrument handle and/or surgical robotic interface. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the surgical stapling assembly 300. The shaft assembly 310 comprises an articulation joint 320. Discussed in greater detail below, the end effector 200 is configured to be articulated relative to an outer shaft 311 of the shaft assembly 310 about axis AA.

The shaft assembly 310 comprises the outer shaft 311, a first shaft joint component 330, and a second shaft joint component 350 pivotally coupled to the first shaft joint component 330 by way of an articulation pin 354. The first shaft joint component 330 comprises a proximal tube portion 331 configured to fit within the inner diameter of the outer shaft 311. Such a fit may comprise a press fit, for example. However, any suitable attachment means can be used. The first shaft joint component 330 also includes a distal portion 332. The distal portion 332 comprises an articulation tab 333 comprising a pin hole 334 defined therein and a hollow passage 335 through which various drive components of the surgical stapling assembly 300 can pass. Such drive components can include articulation actuators, closure actuators, and/or firing actuators for example.

The first shaft joint component 330 is pivotally connected to the second shaft joint component 350 by way of the articulation pin 354. The articulation pin 354 is also received within a pin hole 353 of a proximally-extending articulation tab 351 of the second shaft joint component 350. The pin hole 353 is axially aligned with the pin hole 334. The articulation pin 354 allows the second shaft joint component 350 to be articulated relative to the first shaft joint component 330 about the articulation axis AA. The second shaft joint component 350 further comprises a pin protrusion 352 extending from the proximal-extending articulation tab 351. Discussed in greater detail below, the pin protrusion 352 is configured to be pivotally coupled to an articulation drive system. The second shaft joint component 350 further comprises a distal portion 355 comprising an annular groove 356 configured to receive a retention ring 358. The distal portion 355 also includes a hollow passage 357 through which various drive components of the surgical stapling assembly 300 can pass. The retention ring 358 is configured to hold the first jaw 201 to the second shaft joint component 350 by fitting within the annular groove 211 of the cartridge channel 210 and the annular groove 356 of the second shaft joint component 350.

To articulate the end effector 200 about the articulation axis AA, an articulation bar 360 is provided. The articulation bar 360 may be actuated by any suitable means such as, for example, by a robotic or motorized input and/or a manual handle trigger. The articulation bar 360 may be actuated in a proximal direction and a distal direction, for example. Embodiments are envisioned where the articulation system comprises rotary driven actuation in addition to or, in lieu of, linear actuation. The articulation bar 360 extends through the outer shaft 311. The articulation bar 360 comprises a distal end 361 pivotally coupled to an articulation link 362. The articulation link 362 is pivotally coupled to the pin protrusion 352 extending from the proximally-extending articulation tab 351 off center with respect to the articulation axis AA. Such off-center coupling of the articulation link 362 allows the articulation bar 360 to apply a force to the second joint shaft component 350 to rotate the second shaft joint component 350 and, thus, the end effector 200, relative to the first joint shaft component 330. The articulation bar 360 can be advanced distally to rotate the end effector 200 in a first direction about the articulation axis AA and retracted proximally to rotate the end effector 200 in a second direction opposite the first direction about the articulation axis AA.

The shaft assembly 310 further comprises an articulation component support structure 340 positioned within the articulation joint 320. Such a support structure can provide support to various drive components configured to pass through the articulation joint 320 to the end effector 200 as the end effector 200 is articulated. The support structure 340 may also serve to isolate the drive components from tissue remnants during use.

FIGS. 12-14 depict a surgical stapling assembly 400 comprising a shaft assembly 410 and the end effector 200 of FIGS. 1-8 attached to the shaft assembly 410. The shaft assembly 410 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 410 comprises a single articulation joint and an articulation cable configured to articulate the end effector 200 about the single articulation joint. The surgical stapling assembly 400 is configured to cut and staple tissue. The surgical stapling assembly 400 may be attached to a surgical instrument handle and/or surgical robotic interface. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the surgical stapling assembly 400. The shaft assembly 410 comprises an articulation joint 420. Discussed in greater detail below, the end effector 200 is configured to be articulated relative to an outer shaft 411 of the shaft assembly 310 about an axis AA.

The shaft assembly 410 comprises the outer shaft 411, a first shaft joint component 430, and a second shaft joint component 450 pivotally coupled to the first shaft joint component 430 by way of an articulation pin 454. The first shaft joint component 430 comprises a proximal tube portion 431 configured to fit within the inner diameter of the outer shaft 411. Such a fit may comprise a press fit, for example. However, any suitable attachment means can be used. The first shaft joint component 430 also includes a distal portion 432, which comprises an articulation tab 433 comprising a pin hole 434 defined therein. The distal portion 432 further defines a hollow passage 435 through which various drive components of the surgical stapling assembly 400 can pass. Such drive components can include articulation actuators, closure actuators, and/or firing actuators, for example.

The first shaft joint component 430 is pivotally connected to the second shaft joint component 450 by way of the articulation pin 454. The articulation pin 454 is also received within a pin hole 453 of a proximally-extending articulation tab 451 of the second shaft joint component 450. The articulation pin 454 allows the second shaft joint component 450 to be articulated relative to the first shaft joint component 430 about the articulation axis AA. The second shaft joint component 450 further comprises a drive ring structure 452. The drive ring structure 452 extends from the proximally-extending articulation tab 451 and further defines a portion of the pin hole 453. Discussed in greater detail below, the drive ring structure 452 is configured to be engaged by an articulation drive system. The second shaft joint component 450 further comprises a distal portion 455 comprising an annular groove 456 configured to receive a retention ring 458. A hollow passage 457 through the distal portion 455 is configured to receive various drive components of the surgical stapling assembly 400 therethrough. The retention ring 458 is configured to hold the first jaw 201 to the second shaft joint component 450 by fitting within the annular groove 211 of the cartridge channel 210 and the annular groove 456 of the second shaft joint component 450.

To articulate the end effector 200 about the articulation axis AA, an articulation cable 460 is provided. The articulation cable 460 may be actuated by any suitable means such as, for example, by a robotic input and/or a manual trigger on a handle of a handheld surgical instrument. The articulation cable 460 may comprise an antagonistic actuation profile. In other words, as a first side of the articulation cable 460 is pulled proximally a second side of the articulation cable 460 is allowed to advance distally like a pulley system. Similarly, as the second side is pulled proximally, the first side is allowed to advance distally. The articulation cable 460 extends through the outer shaft 411. The articulation cable 460 is positioned around the drive ring structure 452 and frictionally retained thereon to permit rotation of the second shaft joint component 450 as the articulation cable 460 is actuated. As the articulation cable 460 is actuated, the articulation cable 460 is configured to apply a rotational torque to the drive ring structure 452 of the second joint shaft component 450 and, thus, the end effector 200. Such torque is configured to cause the second joint shaft component 450 to rotate, or pivot, relative to the first joint shaft component 430 thereby articulating the end effector 200 relative to the outer shaft 411. A first side of the articulation cable 460 can pulled to rotate the end effector 200 in a first direction about the articulation axis AA and a second side of the articulation cable 460 can be pulled to rotate the end effector 200 in a second direction opposite the first direction about the articulation axis AA.

The shaft assembly 410 further comprises an articulation component support structure 440 positioned within the articulation joint 420. Such a support structure 440 can provide support to various drive components configured to pass through the articulation joint 420 to the end effector 200 as the end effector 200 is articulated. The support structure 440 may also serve to isolate the drive components from tissue remnants during use.

The surgical stapling assembly 400 further comprises a closure drive shaft segment 475 and a firing drive shaft segment 476 each configured to transmit rotary motion through the articulation joint 420 to the end effector 200. The drive shaft segments 475, 476 are configured to passively expand and contract longitudinally as the end effector 200 is articulated. For example, articulation can cause expansion and contraction of the drive shaft segments 475, 476 to account for the respective longitudinal stretching of or contracting of the length of the drive shafts owing to articulation of the end effector 200 relative to the shaft assembly 410. During expansion and contraction of the drive shaft segments 475, 476, the drive shaft segments 475, 476 maintain rotary driving engagement with corresponding input shafts extending through the outer shaft 411 and output shafts in the end effector 200. In at least one instance, the output shafts comprise the closure screw 251, which is configured to effect grasping, closing, or tissue manipulation with the jaws 201, 203, and the firing screw 261, which is configured to effect clamping of the jaws 201, 203 and firing of the firing member 270.

FIGS. 15-17 depict a surgical stapling assembly 500 comprising a shaft assembly 510 and the end effector 200 of FIGS. 1-8 attached to the shaft assembly 510. The shaft assembly 510 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 510 comprises a single articulation joint and drive shaft segments configured to passively expand and contract. The surgical stapling assembly 500 is configured to cut and staple tissue. The surgical stapling assembly 500 may be attached to a surgical instrument handle and/or surgical robotic interface. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the surgical stapling assembly 500. The shaft assembly 510 comprises an articulation joint 520. Discussed in greater detail below, the end effector 200 is configured to be articulated about an axis AA.

The shaft assembly 510 comprises a first shaft joint component 530 and a second shaft joint component 540 pivotally coupled to the first shaft joint component 530 by way of an articulation pin 543. The first shaft joint component 530 is configured to be attached to a shaft of a surgical instrument assembly and/or a surgical robotic interface. The first shaft joint component 530 comprises a proximal portion 531 and an articulation tab 533 comprising a pin hole 534 defined therein. In at least one instance, the first shaft joint component 530 comprises a hollow passage through which various drive components of the surgical stapling assembly 400 can pass. Such drive components can include articulation actuators, closure actuators, and/or firing actuators for example.

The first shaft joint component 530 is pivotally connected to the second shaft joint component 540 by way of the articulation pin 543. The articulation pin 543 is also received within a pin hole 542 of a proximally-extending articulation tab 541 of the second shaft joint component 540. The articulation pin 543 allows the second shaft joint component 540 to be articulated relative to the first shaft joint component 530 about the articulation axis AA. The second shaft joint component 540 further comprises a distal portion 545 comprising an annular groove 547 configured to receive a retention ring 548 and a hollow passage 546 through which various drive components of the surgical stapling assembly 500 can pass. The retention ring 548 is configured to hold the first jaw 201 to the second shaft joint component 540 by fitting within the annular groove 211 of the cartridge channel 210 and the annular groove 547 of the second shaft joint component 540.

Any suitable articulation drive system can be used to articulate the end effector 200 about axis AA. In at least one instance, the end effector 200 is passively articulated. In such an instance, the end effector 200 may be pressed against tissue, for example, to apply a force to the end effector 200 and cause the end effector 200 to articulate about an articulation axis. In at least one instance, the end effector 200 further comprises a spring configured to apply a neutral biasing force to the second shaft joint segment 540, for example, to cause the end effector 200 to be biased toward an unarticulated configuration.

The surgical stapling assembly 500 further comprises a closure drive shaft segment 575 and a firing drive shaft segment 576 each configured to transmit rotary motion through the articulation joint 520 to the end effector 200. The drive shaft segments 575, 576 are configured to passively expand and contract longitudinally as the end effector 200 is articulated. Articulation causes the drive shaft segments 575, 576 to expand and contract to account for the longitudinal stretching of or contracting of the length of the drive shafts owing to articulation of the end effector 200. During expansion and contraction of the drive shaft segments 575, 576, the drive shaft segments 575, 576 maintain rotary driving engagement with corresponding input shafts and output shafts in the end effector 200. In at least one instance, the output shafts comprise the closure screw 251 and the firing screw 261, which are further described herein.

FIGS. 18-20 depict a surgical stapling end effector assembly 600 comprising a shaft portion 610 and an end effector 600. The end effector assembly 600 is similar in many respects to various other end effector assemblies disclosed herein; however, the end effector assembly 600 comprises a multi-component firing member driven by a flexible firing shaft. The end effector assembly 600 is configured to cut and staple tissue. The end effector assembly 600 may be attached to a surgical instrument handle and/or surgical robotic interface by way of a proximal tab 611 of the shaft portion 610. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the end effector assembly 600. The end effector assembly 600 comprises a cartridge channel jaw 620 and an anvil jaw 660 pivotally mounted to the cartridge channel jaw 620 to clamp tissue between the cartridge channel jaw 620 and the anvil jaw 660.

The cartridge channel jaw 620 comprises a channel 630 comprising a proximal end 631, a staple cartridge 640 configured to store a plurality of staples therein and configured to be received within the channel 630, and a support brace 650 fitted within the staple cartridge 640. The staple cartridge 640 and the support brace 650 are configured to be assembled together prior to installing the staple cartridge 640 into the channel 630. Discussed in greater detail below, the support brace 650 is configured to further support a firing member assembly as the firing member assembly is advanced through the end effector assembly 600.

The anvil jaw 660 is configured to form staples ejected from the staple cartridge 640. The anvil jaw 660 comprises a proximal end 661 comprising a pair of pin holes 662 defined therein configured to receive a coupling pin 663. The anvil jaw 660 is pivotable about the coupling pin 663 between an unclamped position and a fully clamped position. The coupling pin 663 is also received within a pair of pin holes 633 defined in the proximal end 631 of the channel 630. The coupling pin 663 serves to pivotally mount the anvil jaw 660 to the channel 630. In at least one instance, the channel 630 is mounted to the shaft portion 610 by way of a retention ring, or band, that fits around an annular groove 632 of the channel 630 and annular groove 615 of the shaft portion 610. The retention ring, or band, is configured to hold the channel 630 to the shaft portion 610.

The end effector assembly 600 comprises a closure drive 670 configured to grasp tissue between the anvil jaw 660 and the cartridge channel jaw 620 by pivoting the anvil jaw 660 relative to the channel 630. The end effector assembly 600 also includes a firing drive 680 configured to clamp, staple, and cut tissue by deploying a plurality of staples from the staple cartridge 640. The closure drive 670 comprises a closure screw 671 positioned within the channel 630 and a closure wedge 675 threadably coupled to the closure screw 671. As the closure screw 671 is rotated, the closure wedge 675 is advanced distally or retracted proximally to open or close the anvil jaw 660, respectively. The closure drive 670 may be actuated by any suitable means. For example, a rotary drive shaft may extend through the shaft portion 610 from an actuation interface, for example, to rotate the closure screw 671. Other examples of suitable rotary drive shafts are further described herein.

The firing drive 680 comprises a flexible drive shaft 681 that is configured to be moved linearly through the end effector assembly 600. The flexible drive shaft 681 may be actuated by a robotic input and/or a manually-actuated drive shaft of a handle assembly, for example. The flexible drive shaft 681 is configured to extend through a hollow passage 614 of a distal end 613 of the shaft portion 610 and is flexible so that the end effector assembly 600 may be articulated relative to a shaft from which the end effector 600 extends. The flexible drive shaft 681 extends through a clearance slot 676 defined in the closure wedge 675 and is fixedly attached to a lower firing member 682. The lower firing member 682 is configured to be reused with different staple cartridges.

The staple cartridge 640 comprises a disposable upper firing member 683 configured to hookingly engage or, latch, onto the lower firing member 682 such that the lower firing member 582 can push or, drive, the upper firing member 683 through the staple cartridge 640 and support brace 650. In other words, the firing actuation involves a two-part firing member—a disposable upper firing member 683 incorporated into the cartridge 640 and a reusable lower firing member 682 incorporated into the firing drive 680, which can be coupled together when the cartridge 640 is seated in the elongate channel 630. The two-part firing member is further described herein.

The upper firing member 683 comprises an upper flange configured to engage and position the anvil jaw 660, a knife edge configured to cut tissue, and a latch portion configured to hookingly engage the lower firing member 682. The staple cartridge 640 further comprises a sled 684 configured to engage staple drivers positioned within the staple cartridge 640 to eject staples from the staple cartridge 640. Because a knife and cutting edge are incorporated into the disposable upper firing member 683 of the staple cartridge 640, a new and/or fresh cutting edge can be supplied with each staple cartridge loaded into the end effector assembly 600.

The lower firing member 682 and the upper firing member 683 are configured to move through the support brace 650 such that the vertical loads associated with the firing sequence are configured to be distributed through the support brace 650, the staple cartridge 640, the channel 630, and the anvil jaw 660. The support brace 650 may be comprised of a metal material, for example, to be inserted within the staple cartridge 640. The support brace 650 comprises key rails 655 configured to fit within corresponding key slots defined in a longitudinal slot of the staple cartridge 640. The support brace 650 further comprises a longitudinal slot 653 configured to receive the knife of the upper firing member 683, a cylindrical passage 657 configured to receive a portion of the upper firing member 683, a portion of the lower firing member 682, and the flexible drive shaft 681. The support brace 650 further comprises vertical key extensions 656 configured to be received within corresponding key holes in the cartridge deck. Such extensions may be visible through the cartridge deck when the support brace 650 is installed within the staple cartridge 640. In at least one instance, the support brace 650 is configured to be inserted into the staple cartridge 640 from the bottom of the staple cartridge 640 facing the channel 630.

The support brace 650 further comprises a proximal tab 651 and a distal tab 653, which are both configured to be engaged with the channel 630. The tabs 651, 653 are configured to distribute at least some of the forces transmitted through the assembly 600 by the firing drive 680 and corresponding components. The distal tab 651 may serve to block the upper and lower firing members 683, 682 from being pushed through a distal end of the support brace 650 by sharing and/or redistributing the load applied to the support brace 650 by the firing drive 680 with the channel 630.

When the staple cartridge 640 is replaced so that the end effector assembly 600 can be reused, the staple cartridge 640 is removed from the channel jaw 630. Removing the staple cartridge 640 from the channel jaw 630 removes the upper firing member 683, the sled 684, the support brace 650, and the staple cartridge 640. A fresh knife can be provided with a replacement staple cartridge.

Various embodiments disclosed herein may be employed in connection with a robotic system 700. An exemplary robotic system is depicted in FIGS. 21-23, for example. FIG. 21 depicts a master controller 701 that may be used in connection with a surgical robot, such as the robotic arm slave cart 800 depicted in FIG. 22, for example. Master controller 701 and robotic arm slave cart 800, as well as their respective components and control systems are collectively referred to herein as a robotic system 700. Examples of such systems and devices are disclosed in U.S. Pat. No. 7,524,320, entitled MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTIC SURGICAL TOOLS, as well as U.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which are each hereby incorporated by reference herein in their respective entireties. As is known, the master controller 701 generally includes controllers (generally represented as 703 in FIG. 21) which are grasped by the surgeon and manipulated in space while the surgeon views the procedure via a stereo display 702. The controllers 701 generally comprise manual input devices which preferably move with multiple degrees of freedom, and which often further have an actuatable handle, trigger, or actuator for actuating tools (for example, for closing grasping jaws, applying an electrical potential to an electrode, or the like).

As can be seen in FIG. 22, in one form, the robotic arm cart 800 may be configured to actuate one or more surgical tools, generally designated as 900. Various robotic surgery systems and methods employing master controller and robotic arm cart arrangements are disclosed in U.S. Pat. No. 6,132,368, entitled MULTI-COMPONENT TELEPRESENCE SYSTEM AND METHOD, the entire disclosure of which is hereby incorporated by reference herein.

In various forms, the robotic arm cart 800 includes a base 702 from which, in the illustrated embodiment, surgical tools 900 may be supported. In various forms, the surgical tool(s) 900 may be supported by a series of manually articulatable linkages, generally referred to as set-up joints 804, and a robotic manipulator 806. In various embodiments, the linkage and joint arrangement may facilitate rotation of a surgical tool around a point in space, as more fully described in U.S. Pat. No. 5,817,084, entitled REMOTE CENTER POSITIONING DEVICE WITH FLEXIBLE DRIVE, the entire disclosure of which is hereby incorporated by reference herein. The parallelogram arrangement constrains rotation to pivoting about an axis 812 a, sometimes called the pitch axis. The links supporting the parallelogram linkage are pivotally mounted to set-up joints 804 (FIG. 22) so that the surgical tool further rotates about an axis 812 b, sometimes called the yaw axis. The pitch and yaw axes 812 a, 812 b intersect at the remote center 814, which is aligned along an elongate shaft of the surgical tool 900. The surgical tool 900 may have further degrees of driven freedom as supported by the manipulator 806, including sliding motion of the surgical tool 900 along the longitudinal axis “LT-LT”. As the surgical tool 900 slides along the tool axis LT-LT relative to manipulator 806 (arrow 812 c), the remote center 814 remains fixed relative to the base 816 of the manipulator 806. Hence, the entire manipulator is generally moved to re-position the remote center 814. Linkage 808 of manipulator 806 may be driven by a series of motors 820. These motors actively move linkage 808 in response to commands from a processor of a control system. The motors 820 may also be employed to manipulate the surgical tool 900. Alternative joint structures and set up arrangements are also contemplated. Examples of other joint and set up arrangements, for example, are disclosed in U.S. Pat. No. 5,878,193, entitled AUTOMATED ENDOSCOPE SYSTEM FOR OPTIMAL POSITIONING, the entire disclosure of which is hereby incorporated by reference herein.

While the data communication between a robotic component and the processor of the robotic surgical system is primarily described herein with reference to communication between the surgical tool and the master controller 701, it should be understood that similar communication may take place between circuitry of a manipulator, a set-up joint, an endoscope or other image capture device, or the like, and the processor of the robotic surgical system for component compatibility verification, component-type identification, component calibration (such as off-set or the like) communication, confirmation of coupling of the component to the robotic surgical system, or the like. In accordance with at least one aspect, various surgical instruments disclosed herein may be used in connection with other robotically-controlled or automated surgical systems and are not necessarily limited to use with the specific robotic system components shown in FIGS. 21-23 and described in the aforementioned references.

It is common practice during various laparoscopic surgical procedures to insert a surgical end effector portion of a surgical instrument through a trocar that has been installed in the abdominal wall of a patient to access a surgical site located inside the patient's abdomen. In its simplest form, a trocar is a pen-shaped instrument with a sharp triangular point at one end that is typically used inside a hollow tube, known as a cannula or sleeve, to create an opening into the body through which surgical end effectors may be introduced. Such arrangement forms an access port into the body cavity through which surgical end effectors may be inserted. The inner diameter of the trocar's cannula necessarily limits the size of the end effector and drive-supporting shaft of the surgical instrument that may be inserted through the trocar.

Regardless of the specific type of surgical procedure being performed, once the surgical end effector has been inserted into the patient through the trocar cannula, it is often necessary to move the surgical end effector relative to the shaft assembly that is positioned within the trocar cannula in order to properly position the surgical end effector relative to the tissue or organ to be treated. This movement or positioning of the surgical end effector relative to the portion of the shaft that remains within the trocar cannula is often referred to as “articulation” of the surgical end effector. A variety of articulation joints have been developed to attach a surgical end effector to an associated shaft in order to facilitate such articulation of the surgical end effector. As one might expect, in many surgical procedures, it is desirable to employ a surgical end effector that has as large a range of articulation as possible.

Due to the size constraints imposed by the size of the trocar cannula, the articulation joint components must be sized so as to be freely insertable through the trocar cannula. These size constraints also limit the size and composition of various drive members and components that operably interface with the motors and/or other control systems that are supported in a housing that may be handheld or comprise a portion of a larger automated system. In many instances, these drive members must operably pass through the articulation joint to be operably coupled to or operably interface with the surgical end effector. For example, one such drive member is commonly employed to apply articulation control motions to the surgical end effector. During use, the articulation drive member may be unactuated to position the surgical end effector in an unarticulated position to facilitate insertion of the surgical end effector through the trocar and then be actuated to articulate the surgical end effector to a desired position once the surgical end effector has entered the patient.

Thus, the aforementioned size constraints form many challenges to developing an articulation system that can effectuate a desired range of articulation, yet accommodate a variety of different drive systems that are necessary to operate various features of the surgical end effector. Further, once the surgical end effector has been positioned in a desired articulated position, the articulation system and articulation joint must be able to retain the surgical end effector in that locked position during the actuation of the end effector and completion of the surgical procedure. Such articulation joint arrangements must also be able to withstand external forces that are experienced by the end effector during use.

Various surgical instruments employ a variety of different drive shaft arrangements that serve to transmit drive motions from a corresponding source of drive motions that is supported in a handle of the surgical instrument or other portion of an automated or robotically controlled system. These drive shaft arrangements must be able to accommodate significant articulated orientations of the end effector while effectively transmitting such drive motions across the articulation joint of the surgical instrument. In addition, due to the above-mentioned size constraints dictated by the sizes of trocars through which the instrument shafts must be inserted, these drive shaft components must occupy as little space as possible within the shaft. To accommodate such requirements, many drive shaft arrangements comprise several movable elements that are coupled together in series. The small sizes (e.g., 4 mm diameter) and numbers of components lead to difficult and lengthy assembly procedures that add to the cost and complexity of the device.

As further described herein, a powered stapling device can include two independently rotatable drive members: a first rotary drive member configured to effect closing of the jaws of the end effector and a second rotary drive member configured to effect firing of a staple cartridge installed in the end effector. The first and second rotary drive members are flexible and configured to extend through at least one articulation joint. In such instances, the first and second rotary drive members can transmit rotary actuation motions through the articulation joint(s) when in a non-flexed configuration and when in a flexed configuration. Exemplary rotary drive members are further described herein.

The powered stapling assembly further comprises a first jaw, a second jaw, a closure drive comprising the first rotary drive member extending through the articulation joint, and a firing drive comprising the second rotary drive member extending through the articulation joint. The second rotary drive member can be rotatable independent of the first rotary drive member. The closure drive can be activated by a closure trigger, for example, whereupon an actuation of the closure drive effects a rotation of the first rotary drive member, which transmits a rotary motion through the articulation joint to a closure screw. The closure drive further comprises a closure wedge threadably coupled to the closure screw, wherein the closure wedge is configured to engage the first jaw to move the first jaw from an open position to a closed position upon rotation of the first rotary drive member.

The firing drive can be activated by a firing trigger, for example, which is separate from the closure trigger. The rotation of the second rotary drive member is separate from the rotation of the first rotary drive member, and a closure motion is separate and distinct from a firing motion. Activation of the firing drive effects a rotation of the second rotary drive member, which transmits a rotary motion through the articulation joint to a firing screw. The firing drive further comprises a firing member threadably coupled to the firing screw, wherein the firing member is configured to camming engage the first jaw and the second jaw and to move a cutting member and/or a staple-firing sled upon rotation of the second rotary drive member.

In various instances, at least one component in the powered stapling device can be a 3D-printed component. 3D-printed components can be incorporated into an articulation system, a closure/grasping system, and/or a firing system, as further described herein. 3D printing technology can be utilized to improve component capabilities in certain instances. For example, 3D printing can allow the printed component to exhibit metamaterial properties, such that the 3D-printed components exhibits greater structural strength and stiffness while allowing precision in the forming of small detailed features and optimizing other properties of the component such as selective flexibility and/or lubrication, for example. Exemplary 3D-printed components for the powered stapling device are further described herein and include the flexible rotatable drive member(s), e.g. serial 3D-printed universal joints, the firing member or I-beam, and/or the staple cartridge and/or sub-components thereof. In one instance, the staple cartridge can be a composite plastic-metal 3D-printed component. 3D printing of various components and considerations therefor are further described herein.

A method of stapling with such surgical stapling assemblies is also contemplated. The method can include obtaining the surgical stapling assembly and activating, by the closure trigger, the closure drive, wherein the closure wedge is configured to engage the first jaw to move the first jaw from an open position to a closed position upon a rotation of the first rotary drive member. The method can further includes activating, by the firing trigger, the firing drive, wherein the firing member is configured to camming engage the first jaw and the second jaw and to advance a cutting member and a staple-firing sled during a firing motion upon a rotation of the second rotary drive member. Various applications of 3D-printed components in such assemblies are further described herein.

FIGS. 26-29 illustrate one form of a universally movable joint 60200 that may be fabricated by various additive manufacturing process commonly falling under the umbrella term of “three dimensional (3D)” printing. As will become further evident as the present disclosure proceeds, the use of such processes to produce a universally movable joint 60200 that may be employed to form various drive shaft arrangements disclosed herein may address many if not all of the size and assembly challenges discussed above.

Various forms of additive manufacturing systems are known for manufacturing components from sinterable building materials, for example. FIG. 24 illustrates in general form, an additive manufacturing system 60100 that may implement a manufacturing process 60000 for forming a universally movable joint 60200, in accordance with at least one aspect of the present disclosure. As used herein, the term “additive manufacturing” may encompass, but is not limited to, “selective laser melting (SLM),” “direct metal laser melting (DMLM),” “laser powder bed fusion (LPBF),” and various other known systems as well as those systems disclosed for example in U.S. Pat. No. 9,815,118, entitled FABRICATING MULTI-PART ASSEMBLIES, the entire disclosure of which is herein incorporated by reference.

By way of non-limiting example, the additive manufacturing system 60100 comprises a printer 60120 that may include a fused filament fabrication system, a binder jetting system, a stereolithography system, a selective laser sintering system, or any other system that can be usefully adapted or employed to form a universally movable joint 60200 described herein under computer control from or out of a build material 60130. In at least one form, the build material 60130 may comprise sinterable materials commonly employed with such printers. For example, in accordance with various aspects of the present disclosure, the build material 60130 may comprise 316 stainless steel, 17-4 stainless steel, Ti-64 titanium, etc. As will be discussed in further detail below, various other forms of build materials (metal and non-metal) may also be employed.

In one aspect, the additive manufacturing system 60100 may comprise a computer system 60125 that is configured to generate a computer aided design (CAD) three dimensional file of the universally movable joint 60200. The CAD file data may then be sliced into layers forming a two dimensional image of each layer. This file may then be loaded into a file preparation software package that assigns parameters, values, and physical supports that allow the file to be interpreted by the printer 60120. In a general form, the printer 60120 may comprise a build chamber 60122 that includes a build plate or platform 60124 and a laser 60126. In accordance with one non-limiting aspect, the build chamber 60122 may further include a material dispensing platform (not shown) and a re-coater member (not shown) that is used to move new build material 60130 over the build plate 60124. In at least one arrangement, the build material 60130 is commonly in powered form (“first state”) and the laser 60126 fuses the powdered build material 60130 into a solid part (“second state”) by melting it locally using the focused laser beam. For example, the component portions of the universally movable joint 60200 may be built up additively, layer by layer.

Support structures may be required in many additive manufacturing processes to dissipate heat away from the printed component and into the build plate as well as to support the component throughout the manufacturing process. Overhanging features of a printed component generally have no underlying solid layer to support them at any point. Such overhanging features may therefore be more prone to deformation during manufacturing caused by gravity, internal heat, and residual stresses. In such instances, to avoid this deformation, support structures may be employed to support those overhanging features during the additive manufacturing process. While such support structures are useful for these reasons, they must be removed from the formed component or part after the process is completed. This results in wasted material and can lead to increased manufacturing costs.

In one non-limiting example, the additive manufacturing system 60100 may include a conveyor 60140 for transporting a printed “green” universally movable joint 60200G to a post-processing station 60150. As used in this context, the term “green” may refer to a condition of the universally movable joint 60200 wherein one or more component portions thereof lacks one or more of the following attributes: (i) final desired composition, (ii) final desired strength, (iii) final desired dimension(s), (iv) final desired shape, (v) final desired density, and/or (vi) final desired finish, for example. The conveyor 60140 may be any suitable mechanism or combination of devices suitable for physically transporting the green universally movable joint 60200G. This may, for example, include a robotics and a machine vision system or the like on the printer side for detaching the green universally movable joint 60200G from the build plate 60124, as well as robotics and a machine vision system or the like on the post-processing side to accurately place the green universally movable joint 60200G within the post-processing station 60150. In another aspect, the green universally movable joint 60200G may be manually transported between the two corresponding stations.

The post-processing station 60150 may be any system or combination of systems useful for converting the green universally movable joint 60200G into the desired net final shape, net final dimension, net final density, net final strength and/or net final finish, for example. The post-processing station 60150 may also or instead, for example, include a de-binding station such as a chemical de-binding station for dissolving binder materials in a solvent or the like, or more generally, any de-binding station configured to remove at least a portion of the binder system from the various forms of build materials 60130. The post-processing station 60150 may, for example, also or instead include a thermal sintering station for applying a thermal sintering cycle at a sintering temperature for the build material 60130, or the powdered material in the build material 60130, such as a sintering furnace configured to sinter the powdered material into a densified object. The post-processing station may also or instead comprise a heat treating station. The post processing station may also or instead comprise a system for removing unformed build material and/or support material using a variety of different mediums including, but not limited to, liquids, solvents, air pressure, gravity, etc.

Further, a wide range of sintering techniques may be usefully employed by the post-processing station 60150. In one aspect, the green universally movable joint 60200G may be consolidated in a furnace to a high theoretical density using vacuum sintering, for example. In another aspect, the furnace may use a combination of flowing gas (e.g., at below atmosphere, slightly above atmosphere, or some other suitable pressure) and vacuum sintering. More generally, any sintering or other process suitable for improving object density may be used, preferably where the process yields a near-theoretical density part with little or no porosity. Hot-isostatic pressing (“HIP”) may also or instead be employed, e.g., by applying elevated temperatures and pressures as a post-sintering step to increase density of the final part. In another aspect, the universally movable green joint 60200G may be processed using any of the foregoing, followed by a moderate overpressure (greater than the sintering pressure, but lower than HIP pressures). More generally, any technique or combination of techniques suitable for removing binder systems and driving a powdered material toward consolidation and densification may be used by the post-processing station 60150 to process a fabricated universally movable joint 60200 as contemplated herein.

The post-processing station 60150 may also or instead comprise machining operations configured to remove support structure(s) (if any) and/or machine the component portions of the green universally movable joint 60200G that have been printed within “near net” dimensions to provide the joint components with final desired dimensions and shapes. The post-processing station 60150 may also or instead include a Directed Energy Deposition (DED) process which in one form may comprise a three dimensional (3D) printing method that employs a focused energy source, such as a plasma arc, laser or electron beam to melt a material which is simultaneously deposited by a nozzle. Such DED process may be used for example to repair or add additional material to a green universally movable joint 60200G or finished universally movable joint 60200. The post-processing station 60150 may also or instead comprise various grit blasting and/or polishing operations for attaining a desired final surface finish of the universally movable joint 60200.

FIG. 25 illustrates one non-limiting example of a manufacturing process 60000 for forming a universally movable joint 60200. In one general aspect, the manufacturing process 60000 comprises the action 60010 of developing a computer aided designed (CAD) file of the universally movable joint 60200 in a format that is useable by the printer 60120. The manufacturing process 60000 further includes the action 60020 of implementing the computer designed file to cause the printer 60120 to form a green universally movable joint 60200G from build material 60130 that is supplied to the build chamber 60122 of the printer 60120. In at least one non-limiting form, the manufacturing process 60000 may further comprise the action 60030 of post-processing the green universally movable joint 60200G to form a final universally movable joint 60200 as described and contemplated herein. The action 60030 may include one or more actions described herein designed to provide the green universally movable joint 60200G and the components thereof with a final desired composition, strength, shape, dimensions, density, and/or finish, for example.

FIGS. 26-29 illustrate a completed or finished universally movable joint 60200 that was formed using the additive manufacturing system 60100. As shown in FIGS. 26-29, one form of the universally movable joint 60200 comprises a cross-shaped joint spine 60300, a vertical U-joint 60400 and a horizontal U-joint 60500. In at least one embodiment, for example, the joint spine 60300 defines a vertical axis VA-VA and a horizontal axis HA-HA that is transverse to the vertical axis VA-VA. In one arrangement, the horizontal axis HA-HA is orthogonal to the vertical axis VA-VA. As can be seen in FIGS. 27 and 29 for example, the joint spine 60300 comprises a bottom axle segment 60310 that is axially aligned on the vertical axis VA-VA and includes a flared bottom end 60312. The flared bottom end 60312 defines an arcuate bottom surface 60314. The joint spine 60300 further comprises a top axle segment 60320 that is axially aligned on the vertical axis VA-VA and includes a flared top end 60322 that defines an arcuate top surface 60324. The joint spine 60300 further comprises a first or right horizontal axle segment 60330 that is axially aligned on the horizontal axis HA-HA and terminates in a first conical end portion 60334. The joint spine 60300 also comprises a second or left horizontal axle segment 60340 that is axially aligned on the horizontal axis HA-HA and terminates in a second conical end portion 60344.

Still referring to FIGS. 28 and 29, the vertical U-joint 60400 in at least one form comprises a bottom “wishbone” or bottom joint ring 60410 that is journaled on the bottom axle segment 60310 for rotation therearound. The flared bottom end 60312 of the joint spine 60300 permanently retains the bottom joint ring 60410 on the bottom axle segment 60310. In one non-limiting example, the vertical U-joint 60400 further comprises a top “wishbone” or top joint ring 60420 that is journaled on the top axle segment 60320 for rotation therearound. The flared top end 60322 of the joint spine 60300 permanently retains the top joint ring 60420 on the top axle segment 60320. The vertical U-joint 60400 further comprises a U-shaped vertical bridge 60430 that protrudes from the bottom joint ring 60410 and the top joint ring 60420 and extends therebetween. The U-shaped vertical bridge 60430 comprises an arcuate outer surface 60431 that serves to facilitate pivotal travel and movement of the vertical U-joint 60400 with the tight confines of a hollow outer shaft portion of a surgical instrument and/or surgical trocar. The vertical U-joint 60400 comprises one integrally formed component of the universally movable joint 60200 that is rotatable about the vertical axis VA-VA of the joint spine 60300 and is permanently retained thereon by the flared bottom end 60312 and the flared top end 60322 as well as the U-shaped vertical bridge 60430. Stated another way, the vertical U-joint 60400 cannot be detached from the joint spine 60300 without damaging one or both of those components.

In accordance with another aspect of the present disclosure, the horizontal U-joint 60500 in at least one form comprises a first horizontal “wishbone” or joint cap 60510 that is rotatably journaled on the first horizontal axle segment 60330 and a second horizontal “wishbone” or joint cap 60520 that is rotatably journaled on the second horizontal axle segment 60340. The horizontal U-joint 60500 further comprises a U-shaped horizontal bridge 60530 (FIG. 26) that protrudes from the first horizontal joint cap 60510 and the second horizontal joint cap 60520 and extends therebetween. The U-shaped horizontal bridge 60530 comprises an arcuate (as opposed to a flat) outer surface 60531 that serves to facilitate pivotal travel and movement of the horizontal U-joint 60500 with the tight confines of a hollow outer shaft portion of a surgical instrument and or surgical trocar. The horizontal U-joint 60500 comprises one integrally formed component of the universally movable joint 60200 that is rotatable about the horizontal axis HA-HA of the joint spine 60300 and is permanently retained thereon by the U-shaped horizontal bridge 60530. See FIG. 26. Stated another way, the horizontal U-joint 60500 cannot be detached from the joint spine 60300 without damaging one or both of those components.

Turning to FIG. 29, in at least one non-limiting example, the bottom joint ring 60410 comprises a bottom ring inner surface 60412 that is spaced from an outer surface 60316 of the bottom axle segment 60310 to define a bottom joint space 60318 that extends between the bottom joint ring 60410 and the bottom axle segment 60310 and opens to the bottom of the universally movable joint 60200 around the flared bottom end 60312. Similarly, the top joint ring 60420 comprises a top ring inner surface 60422 that is spaced from an outer surface 60323 of the top axle segment 60320 to define a top joint space 60326.

Still referring to FIG. 29, in accordance with another non-limiting example, the first horizontal joint cap 60510 comprises a first hub portion 60512 that comprises a first hub inner surface 60514 and a first cap portion 60516 that defines a first tapered end surface 60518. The first hub inner surface 60514 is spaced from an outer surface 60332 of the first horizontal axle segment 60330 and the first tapered end surface 60518 is spaced from the first conical end portion 60334 to define a first horizontal joint space 60336 that extends between the first horizontal joint cap 60510 and the first horizontal axle segment 60330 and the first conical end portion 60334. The first horizontal joint space 60336 opens through a first hole 60519 in the first cap portion 60516.

Similarly, the second horizontal joint cap 60520 comprises a second hub portion 60522 that comprises a second hub inner surface 60524 and a second cap portion 60526 that defines a second tapered end surface 60528. The second hub inner surface 60524 is spaced from an outer surface 60342 of the second horizontal axle segment 60340 and the second tapered end surface 60528 is spaced from the second conical end portion 60344 to define a second horizontal joint space 60346 that extends between the second horizontal joint cap 60520 and the first horizontal axle segment 60340 and the first conical end portion 60344. The second horizontal joint space 60346 opens through a second hole 60529 in the second cap portion 60526.

As can also be seen in FIG. 27, in a non-limiting example, the bottom joint ring 60410 comprises a bottom joint ring outer surface 60414. The top joint ring 60420 comprises a top joint ring outer surface 60424. The first horizontal joint cap 60510 comprises a first cap outer surface 60517 and the second horizontal joint cap 60520 comprises a second outer cap surface 60527. In the illustrated example, the bottom joint ring outer surface 60414 is spaced from the first cap outer surface 60517 to define a first lower clearance space or “fillet” 60416 therebetween. Likewise, the bottom joint ring outer surface 60414 is spaced from the second cap outer surface 60527 to define a second lower clearance space or “fillet” 60418 therebetween. The top joint ring outer surface 60424 is spaced from the first cap outer surface 60517 to define a first upper clearance space or “fillet” 60426 therebetween. Likewise, the top joint ring outer surface 60424 is spaced from the second cap outer surface 60527 to define a second upper clearance space or “fillet” 60428 therebetween.

FIG. 30 illustrates a green universally movable joint 60200G that is still supported on the build plate 60124. In this example, one form of build material 60130 is employed. In a “first state”, the build material 60130 comprises a powder material of the various types disclosed and contemplated herein. Once transformed by the laser or other component/system, for example, the build material 60130 comprises a “second” state. As shown in FIG. 30, various amounts of the build material 60130 in powder form, e.g., the “first state” (referred to in FIG. 30 as “60130U”) are located in the top joint space 60326, the first upper clearance space 60426, the second upper clearance space 60428, the first horizontal joint space 60336, the second horizontal joint space 60346, the first lower clearance space 60416, the second lower clearance space 60418, and the bottom joint space 60318. Such amounts of unformed build material 60130U serve to support the vertical U-joint 60400 and the horizontal U-joint 60500 on the joint spine 60300 during the printing process and prevents those components from become fused or non-movably formed together. After the green universally movable joint 60200G has been formed, these amounts of unformed build material 60130U must be removed from between the vertical U-joint 60400 and the joint spine 60300 and the horizontal U-joint 60500 and the joint spine 60300. In various instances, the amounts of unformed build material 60130U may be removed under the influence of gravity and/or may be removed using a removal medium (air, liquid, solvent, etc.) during post processing. In one aspect, the first lower clearance or fillet 60416, the second lower clearance or fillet 60418, the first upper clearance space or fillet 60426, the second upper clearance space or fillet 60428 as well as the hole 60519 in the first horizontal joint cap 60510 and the second hole 60529 in the second horizontal joint cap 60520 serve to facilitate easy removal the amounts of build material 60130U from the green universally movable joint 60200G. See FIGS. 30A-30C.

During the printing process or formation process, the joint spine 60300 extends from the built plate 60124 and is formed vertically off the build plate 60124. The flared bottom end 60312 is formed off of the build plate 60124 and is attached thereto during formation. The flared bottom end 60312 serves to support the joint spine 60300 during the printing process. In one aspect, unformed build material 60130U around the flared bottom end 60312, the bottom joint ring 40410, the first horizontal joint cap 60510 and the second horizontal joint cap 60520, as well as the amounts of unformed build material 60130U in the spaces between the vertical U-joint 60400, the horizontal U-joint 60500, and the joint spine 60300 may further help to maintain the vertical orientation of the joint spine 60300 (and the universally movable joint 60200G) during the forming process without the use of support members between the joint components and the build plate 60124. In such arrangement, the flared bottom end 60312 facilitates thermal dissipation into the build plate 60124. The bottom joint ring 60410 is formed without being attached to the build plate 60124. In accordance with at least one aspect, universally movable joints 60200 having an overall diameter of as small as approximately 4mm may be formed in such a manner. Joints with larger diameters, for example, of approximately 10mm or more may require one or more support members to support the joint components in a vertical orientation during the printing process. In any event, once the amounts of unformed (i.e., still in a first state or powder form or unsolidified) build material 60130U are removed from between the joint components, the vertical U-joint 60400 is freely rotatable on the joint spine 60300 about the vertical axis VA-VA and the horizontal U-joint 60500 is freely rotatable about the joint spine 60300 about the horizontal axis HA-HA. In addition, the vertical U-joint 60400 and the horizontal U-joint 60500 cannot be removed from the joint spine 60300 without damaging the universally movable joint 60200.

FIG. 31 illustrates a non-limiting example wherein support members 60600 are formed between the flared bottom end 60312 and the build plate 60124, and/or between the bottom joint ring 60410 and the build plate 60124, and/or between the first horizontal joint cap 60510 and the build plate 60124, and/or between the second horizontal joint cap 60520 and the build plate 60124. The shapes, numbers, and compositions of such support members can vary and are configured to be removed from the universally movable joint 60200G′ during post processing. In such arrangement, various amounts 60130U of unformed building material may be received in the above-described spaces between the joint components and thereafter removed during post processing.

FIG. 32 illustrates a green universally movable joint 60200G formed from a build material 60130 of the types disclosed and contemplated herein. However, during this manufacturing process, a support material SM is introduced during the process to separate components 60300, 60400, 60500 during printing. Such support material SM may comprise a powdered support material that may be removed from the spaces between the components under the influence of gravity, air pressure, liquid, etc. Other support materials SM that may be dissolved when contacted by a solvent medium are contemplated.

Other non-limiting systems and processes are contemplated wherein a universally movable joint 60200 is formed from different build materials and different support materials. For example, FIG. 33 illustrates a universally movable joint 60200′ that is identical to universally movable joint 60200 except for the differences noted below relating to its composition and formation. For example, the joint spine 60300′ may be formed from a first build material FBM and the vertical U-joint 60400′ and/or the horizontal U-joint member 60500′ may be fabricated from a second build material SBM that is different from the first build material FBM. For example, the first build material FBM may comprise a polymer and the second build material may comprise a metal build material or vice versa. The first build material FBM and the second build material SBM may be introduced in precise locations on the build plate 60124 at predetermined times and locations to facilitate printing of the components from the desired materials. In other arrangements, one of the components may be printed from the first build material FBM and thereafter the second build material SBM is introduced to form the second component(s). In one contemplated arrangement, for example, the joint spine 60300′ may be printed from a material that is softer than the material used to form the vertical U-joint 60400′ and/or the horizontal U-joint member 60500′. For example, in one arrangement, the joint spine 60300′ is printed from a polymer material or softer material such as brass or bronze, etc. and the vertical U-joint 60400′ and horizontal U-joint 60500′ may be printed from a stainless steel, titanium, or other metal material, etc. Such combination of materials may result in reduced friction between these components. In still other arrangements, the joint spine 60300′ may be fabricated from stainless steel, titanium, etc. and the vertical U-joint 60400′ and the horizontal U-joint 60500′ may be formed from softer materials such as brass, bronze, polymer, etc. Such arrangements may also employ a support material SM of the types contemplated herein to separate the component parts and thereafter be removed from between those component parts during post-processing operations.

FIGS. 34-36, illustrate another form of universally movable joint 60200″ that is identical to universally movable joint 60200 except that the bottom end 60312″ is not flared and the top end 60322″ is not flared. The vertical U-joint 60400 is retained on the joint spine by the U-shaped vertical bridge 60430.

The various forms of universally movable joints 60200, 60200′, 60200″ represent vast improvements over prior joint arrangements that have been employed in various drive shafts and/or articulation joints of surgical instruments. The universally movable joints 60200, 60200′, 60200″ comprise a compact “integral” design that may avoid many of the challenges and increased costs associated with assembling other multiple part shaft/joint arrangements that may be employed in many surgical devices. The design of each of the universally movable joints 60200, 60200′, 60200″ minimize/eliminate unsupported horizontal surfaces, which could otherwise lead to increased surface roughness and component warping. The universally movable joints 60200, 60200′, 60200″ may be printed from metal build material and exhibit strength characteristics that are comparable to or exceed the strength characteristics of multiple part joints that are machined from similar metal material and assembled together with pins, screws, welding, etc. The present joint designs further minimize and, in many cases, eliminate the need for numerous, elaborate support members during the printing process and can also reduce post-processing operations and/or costs.

FIG. 37 illustrates a universally movable drive shaft segment 60700 that comprises multiple movable universally movable joints 60200A, 60200B, and 60200C that are printed in series in one single continuous manufacturing system of the types contemplated herein. In one non-limiting example, universally movable joint 60200A is substantially identical to universally movable joint 60200 described herein except that the U-shaped vertical bridge 60430A is formed with a U-shaped horizontal bridge 60530B of the universally movable joint 60200B. A U-shaped vertical bridge 60430B of the universally movable joint 60200B is formed with a U-shaped horizontal bridge 60530C of the universally movable joint 60200C. In the illustrated non-limiting example, the universally movable joints 60200B and 600200C may otherwise be identical in construction, fabrication, and operation to universally movable joint 60200. The universally movable drive shaft segment 60700 may comprise additional universally movable joints formed in series and is not limited to three joints formed in series. The universally movable drive shaft segment 60700 may comprise two universally movable joints, three or more than three universally movable joints serially formed together using the methods and processes contemplated herein.

FIGS. 38-40 illustrate one form of an articulation joint assembly 61000 that may be employed in the various surgical instruments disclosed and contemplated herein as well as other surgical instrument arrangements, devices, and configurations. In one non-limiting example, the articulation joint assembly 61000 comprises a proximal mounting member 61100 that is configured to interface with a shaft assembly 61010 of a surgical instrument. For example, the proximal mounting member 61100 may be welded or attached to a distal portion of the shaft assembly 61010 by any suitable means. See FIG. 39. In other arrangements, the proximal mounting member 61100 may comprise a portion of the shaft assembly 61010. Also in a non-limiting example, the articulation joint assembly 61000 further comprises a distal mounting member 61200 that is configured to interface with a surgical end effector 61020. The surgical end effector 61020 may comprise any of the surgical end effectors disclosed or contemplated herein and may comprise, but is not limited to, end effectors configured to manipulate tissue (graspers), end effectors configured to cut and staple tissue (endocutters), clip appliers, and end effectors configured to cut and fasten tissue with ultrasound, harmonic, radio frequency energy, etc. The distal mounting member 61200 may be welded or attached to a proximal portion of the surgical end effector 61020 by any suitable means. In other arrangements, the distal mounting member 61200 may comprise a portion of the surgical end effector 61020.

In the non-limiting example illustrated in FIGS. 38-40, the proximal mounting member 61100 comprises a proximal shaft hole 61110 that is axially aligned with a shaft axis SA-SA that is defined by the shaft assembly 61010. Similarly, the distal mounting member 61200 comprises a distal shaft hole 61210. The distal shaft hole 61210 may have a diameter that is the same or similar to a diameter of the proximal shaft hole 61110. The proximal shaft hole 61110 and the distal shaft hole 61210 are sized and configured to accommodate various flexible or otherwise movable drive shafts, actuator components, conductors, cables, shaft support structures, etc. that extend from the shaft assembly 61010 to the surgical end effector 61020. In various instances, such drive shafts, actuators, conductors etc. may be operably supported in one or more flexible hollow conduits or support members that span between the proximal mounting member 61100 and the distal mounting member 61200 for example. In other arrangements the drive shafts are supported in one of the shaft guides described below and contemplated herein. When the surgical end effector 61020 is aligned on the shaft axis SA-SA with the shaft assembly 61010, the distal shaft hole 61210 is aligned with the proximal shaft hole 61110.

Still referring to FIGS. 38-40, in at least one non-limiting example, the articulation joint assembly 61000 further comprises a plurality of articulation link assemblies that are attached to and extend between the proximal mounting member 61100 and the distal mounting member 61200. The illustrated non-limiting example comprises three articulation link assemblies 61300A, 613008, and 61300C. Other numbers of articulation link assemblies are contemplated. Unless otherwise noted herein, the articulation link assemblies 61300A, 61300B, 61300C are similar in construction and in at least one instance, may each be formed or printed using the manufacturing systems of the types contemplated herein. Articulation link assembly 61300A comprises a proximal movable joint 62200A and a distal movable joint 63200A that are very similar in construction and design to the universally movable joints 60200 described herein. For example, a proximal movable joint 62200A comprises a proximal joint spine 62300A, a proximal first joint member 62400A, and a proximal second joint member 62500A. Similarly, each distal movable joint 63200A comprises a distal joint spine 63300A, a distal first joint member 63400A, and a distal second joint member 63500A. In an illustrated non-limiting example, the vertical U-joint 62400A of the proximal first joint member 62400A and the vertical U-joint 63400A of the distal first joint member 63400A may be similar in design to the vertical U-joint 60400 described above, except that a link member 62600A protrudes from a proximal first bridge member 62430A of the proximal first joint member 62400A and a distal first bridge member 63430A of the distal first joint member 63400A and extends therebetween. In one instance, the link member 62600A comprises a circular cross-sectional shape. The circular cross-sectional shape better facilitates passage of operation shafts and control members in the area defined between the link members 62600A, 62600B, 62600C, as will be further discussed below. The proximal first joint member 62400A is configured to pivot relative to the proximal joint spine 62300A about a first proximal axis FPA-FPA and the distal first joint member 63400A is configured to pivot relative to the distal joint spine 63300A about a first distal axis FDA-FDA.

As can be further seen in FIGS. 38-40, the proximal second joint member 62500A may be similar in design to the horizontal U-joint 60500 described above, except that a mounting feature 62700A protrudes from a proximal second bridge member 62530A of the proximal second joint member 62500A. In one non-limiting example, the mounting feature 62700A is configured to be received in a corresponding proximal axial mounting slot 61120A provided in the proximal mounting member 61100. To facilitate easy assembly, the proximal mounting feature 62700A comprises a hook portion 62702A that is configured to hook over a retaining lug 61122A formed in the proximal axial mounting slot 61120A. In one arrangement, the hook portion 62702A is spaced from the proximal second bridge member 62530A by a tapered opening 62704A and is configured to interface with the retaining lug 61122A which is wedge-shaped to non-movably wedgingly affix the proximal movable joint 62200A to the proximal mounting member 61100. In one aspect, the wedge-shaped interface may be sufficient to non-movably couple the proximal movable joint 62200A to the proximal mounting member 61100. In other arrangements, in addition to the wedge-shaped interface, the mounting feature 62700A in the alternative to or in addition to may be affixed to the proximal mounting member 61100 by welding, adhesive or other suitable mounting means. In one instance, the mounting features 62700A may simply be retained in hooking engagement with the proximal mounting member 61100 and the distal mounting member 61200 by a conduit or shaft guide that extends through the proximal shaft hole 61110 and the distal shaft hole 61210. In still other arrangements, the proximal mounting feature 62700A may comprise a stem feature (not shown) configured to be movably inserted into a corresponding axial slot (not shown) in the proximal mounting member 61100 to facilitate axial movement of the proximal movable joint 62200A relative to the proximal mounting member 61100. In at least one non-limiting example, the distal movable joint 63200A may be similarly constructed and coupled to the distal mounting member 61200 and will not be repeated in detail herein. In various instances, when a shaft guide or hollow conduit extends between the proximal mounting member 61100 and the distal mounting member 61200, the conduit or shaft guide serves to prevent the proximal mounting features 62700A from disengaging from the proximal mounting member 61100 and the distal mounting features from disengaging from the distal mounting member 61200.

Articulation link assemblies 61300B and 61300C are similar in design to the articulation link assembly 61300A described in detail above. As can be seen in FIGS. 38-40, the proximal movable joint 62200A of the articulation link assembly 61300A is attached to the proximal mounting member 61100 at a first proximal attachment location FPA defined by the axial mounting slot 61120A. Likewise, the distal movable joint 63200A of the articulation assembly 61300A is formed with a distal mounting feature (not shown) that is similar to the proximal mounting feature 62700A for attachment to the distal mounting member 61200. The distal movable joint 63200A is attached to the distal mounting member 61200 at a first distal attachment location FDA that is defined by a distal axial mounting slot 61220A in the distal mounting member 61200.

Still referring to FIGS. 38-40, the proximal movable joint 62200B of the articulation link assembly 61300B is attached to the proximal mounting member 61100 at a second proximal attachment location SPA defined by a proximal axial mounting slot 61120B and the proximal movable joint 62200C of the articulation link assembly 61300C is attached to the proximal mounting member 61100 at a third proximal attachment location TPA defined by a proximal axial mounting slot 61120C. In one non-limiting example, the first proximal attachment location FPA, the second proximal attachment location SPA, and the third proximal attachment location TPA are equally spaced about the shaft axis SA-SA. Stated another way, angles A, B, and C are each approximately 120°. Similarly, the distal movable joint 63200B of the articulation link assembly 61300B is attached to the distal mounting member 61200 at a second distal attachment location SDA defined by a distal axial mounting slot 61220B and the distal movable joint 63200C of the articulation link assembly 61300C is attached to the distal mounting member 61200 at a third distal attachment location TDA defined by a distal axial mounting slot 61220C. In one non-limiting example, the first distal attachment location FDA, the second distal attachment location SDA, and the third distal attachment location TDA are equally spaced about the shaft axis SA-SA—angles D, E, and F are each approximately 120°. In one arrangement, when the surgical end effector 61020 is in an unarticulated position or, stated another way, axially aligned with the shaft assembly 61010 on the shaft axis SA-SA, the first distal attachment location FDA is diametrically opposite to the first proximal attachment location FPA; the second distal attachment location SDA is diametrically opposite to the second proximal attachment location SPA; and the third distal attachment location TDA is diametrically opposite to the third proximal attachment location TPA. In such arrangement, each of the link members 62600A, 62600B, and 62600C may be slightly twisted around an open central tunnel area 62800 defined by the shaft holes to accommodate unencumbered passage and operation of various drive shafts and other components from the shaft assembly 61010 to the surgical end effector 61020. Stated another way, in at least one arrangement, the axis of each of the link members 62600A, 62600B, are not parallel with each other and are not parallel with the shaft axis SA-SA. In one instance, the distal mounting member 61200 is rotatable relative to the proximal mounting member 61100 during articulation to maintain the inner drive radius of the open central tunnel or open area 62800. In such arrangement, an axial distance AD between the proximal mounting member 61100 and the distal mounting member 61200 is constant throughout the articulation motions/orientations of the articulation joint assembly 61000. See FIG. 40.

To facilitate articulation of the end effector, at least two and preferably four flexible articulation actuators (not shown) are attached to the distal mounting member and movably extend through openings in the proximal mounting member to communicate with an articulation control system supported in or by the housing or robotic system. For example, the flexible articulation actuators may comprise flexible cables configured in the various manners contemplated herein and described in further detail below. Other suitable articulation drive systems may be employed.

FIG. 41 illustrates another form of an articulation joint assembly 64000 that is somewhat similar in design and use to the articulation joint assembly 61000 described above. In one non-limiting example, the articulation joint assembly 64000 comprises a proximal mounting member 64100 that is configured to interface with a shaft assembly 64010 of a surgical instrument. For example, the proximal mounting member 64100 may be welded or attached to a distal portion of the shaft assembly 64010 by any suitable means. In other arrangements, the proximal mounting member 64100 may comprise a portion of the shaft assembly 64010. Also in a non-limiting example, the articulation joint assembly 64000 further comprises a distal mounting member 64200 that is configured to interface with a surgical end effector 64020. The surgical end effector 64020 may comprise any of the surgical end effectors disclosed or contemplated herein and may comprise, but is not limited to, end effectors configured to manipulate tissue (graspers), end effectors configured to cut and staple tissue (endocutters), clip appliers, and end effectors configured to cut and fasten tissue with ultrasound, harmonic, radio frequency energy, etc. The distal mounting member 64200 may be welded or attached to a proximal portion of the surgical end effector 64020 by any suitable means. In other arrangements, the distal mounting member 64200 may comprise a portion of the surgical end effector 64020.

In the non-limiting example illustrated in FIG. 41, the proximal mounting member 64100 comprises a proximal shaft hole 64110 that is axially aligned with a shaft axis SA-SA defined by the shaft assembly 64010. Similarly, the distal mounting member 64200 comprises a distal shaft hole 64210. The distal shaft hole 64210 may have a diameter that is the same or similar to a diameter of the proximal shaft hole 64110. The proximal shaft hole 64110 and the distal shaft hole 64210 are sized and configured to accommodate various flexible or otherwise movable drive shafts, actuator components, conductors, cables, shaft support structures, etc. that extend from the shaft assembly 64010 to the surgical end effector 64020. When the surgical end effector 64020 is aligned on the shaft axis SA-SA with the shaft assembly 64010, the distal shaft hole 64210 is aligned with the proximal shaft hole 64110.

Still referring to FIG. 41, in at least one non-limiting example, the articulation joint assembly 64000 further comprises a plurality of articulation link assemblies that extend between the proximal mounting member 64100 and the distal mounting member 64200 and are attached thereto. The illustrated non-limiting example comprises three articulation link assemblies 64300A, 64300B, and 64300C that, in at least one instance, may each be formed or printed using the manufacturing systems of the types contemplated herein. Other numbers of articulation link assemblies are contemplated. For example, an articulation joint assembly that only comprises two articulation link assemblies will work, but such articulation joint assembly may only facilitate articulation through a single plane. Unless otherwise noted herein, the articulation link assemblies 64300A, 64300B, 64300C are similar in construction. Articulation link assembly 64300A comprises a proximal movable joint 65200A and a distal movable joint 66200A that are very similar in construction and design to the universally movable joints 60200 described herein. For example, a proximal movable joint 65200A comprises a proximal joint spine 65300A, a proximal first joint member 65400A, and a proximal second joint member 65500A. Similarly, each distal movable joint 66200A comprises a distal joint spine 66300A, a distal first joint member 66400A, and a distal second joint member 66500A. In an illustrated non-limiting example, the U-Joint 65400A of the proximal movable joint 65200A and the U-joint 65400B of the distal movable joint 66200A may be similar in design to the U-joint 60400 described above, except that a link member 65600A protrudes from a proximal first bridge member 65430A of the proximal first joint member 65400A and a distal first bridge member 66420A of the distal first joint member 66400A and extends therebetween. The proximal first joint member 65400A is configured to pivot relative to the proximal joint spine 65300A about a first proximal axis and the distal first joint member 66400A is configured to pivot relative to the distal joint spine 66300 about a first distal axis in the manners disclosed herein. In other embodiments, the mounting feature 65700A may comprise a hook-type feature disclosed herein.

As can be further seen in FIG. 41, the proximal second joint member 65500A may be similar in design to the horizontal U-joint 60500 described above, except that a mounting feature 65700A protrudes from a proximal second bridge member 65530A of the proximal second joint member 65500A. In one non-limiting example, the mounting feature 65700A is configured to be received in a corresponding proximal axial mounting hole 64120A provided in the proximal mounting member 64100. Such arrangement facilitates easy assembly and may, in at least one alternative arrangement, permit axial movement of the articulation link 64300A relative to the proximal mounting member 64100.

Articulation link assemblies 64300B and 64300C are similar in design to the articulation link assembly 64300A described in detail above. As can be seen in FIG. 41, the proximal movable joint 65200A of the articulation link assembly 64300A is attached to the proximal mounting member 64100 at a first proximal attachment location FPA defined by the axial mounting slot 64120A. Likewise, the distal movable joint 66200A of the articulation assembly 64300A is formed with a distal mounting feature 66700A that is similar to the proximal mounting feature 62700A for axially movable attachment to the distal mounting member 64200. The distal movable joint 65200A is attached to the distal mounting member 64200 at a first distal attachment location FDA that is defined by a distal axial mounting slot 64220A in the distal mounting member 64200. In one instance, the link assemblies 64300A, 64300B, 64300C may be compressed between the proximal mounting member 64100 and the distal mounting member 64200 during assembly. In such arrangement, an axial distance between the proximal mounting member 64100 and the distal mounting member 64200 is constant throughout the articulation motions/orientations of the articulation joint assembly 64000. In other instances, the proximal mounting member 64100 and the distal mounting member 64200 may be spaced from each other a desired distance so as to permit some limited axial movement of the link assemblies 64300A, 64300B, 64300C.

Still referring to FIG. 41, the proximal movable joint 65200B of the articulation link assembly 64300B is attached to the proximal mounting member 64100 at a second proximal attachment location SPA defined by a proximal axial mounting slot 64120B and the proximal movable joint 65200C of the articulation link assembly 64300C is attached to the proximal mounting member 64100 at a third proximal attachment location TPA defined by a proximal axial mounting slot 64120C. In one non-limiting example, the first proximal attachment location FPA, the second proximal attachment location SPA, and the third proximal attachment location TPA are equally spaced about the shaft axis SA-SA. Similarly, the distal movable joint 66200B of the articulation link assembly 64300B is attached to the distal mounting member 64200 at a second distal attachment location SDA defined by a distal axial mounting slot 64220B and the distal movable joint 66200C of the articulation link assembly 64300C is attached to the distal mounting member 64200 at a third distal attachment location TDA defined by a distal axial mounting slot 64220C. In one non-limiting example, the first distal attachment location FDA, the second distal attachment location SDA, and the third distal attachment location TDA are equally spaced about the shaft axis SA-SA. In one arrangement, when the surgical end effector 64020 is in an unarticulated position or, stated another way, axially aligned with the shaft assembly 64010 on the shaft axis SA-SA, the first distal attachment location FDA is diametrically opposite to the first proximal attachment location FPA; the second distal attachment location SDA is diametrically opposite to the second proximal attachment location SPA; and the third distal attachment location TDA is diametrically opposite to the third proximal attachment location TPA. In such arrangement, each of the link members 65600A, 65600B, and 65600C are slightly twisted around an open central tunnel or open area 65800 defined by the shaft holes 64110, 64210 to accommodate unencumbered passage and operation of various drive shafts and other components from the shaft assembly 64010 to the surgical end effector 64020. Stated another way, in at least one arrangement, the axis of each of the link members 62600A, 62600B, are not parallel with each other and are not parallel with the shaft axis SA-SA. In one instance, the distal mounting 64200 is rotatable relative to the proximal mounting member 64100 during articulation to maintain the inner drive radius of the open central tunnel or open area 65800.

To facilitate articulation of the end effector, at least two and preferably four flexible articulation actuators (not shown) are attached to the distal mounting member 64200 and movably extend through openings in the proximal mounting member 64100 to communicate with an articulation control system supported in or by the housing or robotic system. For example, the flexible articulation actuators may comprise flexible cables configured in the various manners contemplated herein and described in further detail below. Other suitable articulation drive systems may also be employed.

FIGS. 42 and 43 depict another non-limiting arrangement for coupling one of the movable joint members disclosed herein to a mounting member 67100 that may be attached to a portion of a shaft assembly or a portion of a surgical end effector in the various manners disclosed herein. In the illustrated example, the mounting member 67100 comprises an axial slot 67120 that corresponds to each universally movable joint 60200″ that is to be coupled thereto. Each slot 67120 has a stop 67122 formed therein to limit axial travel in one direction. The universally movable joint 60200″ is substantially identical to the universally movable joints 60200, 60200′ described herein except that a mounting stem or mounting feature 67700 protrudes from the U-shaped vertical bridge 60430 of the vertical U-joint 60400. A stop block 67702 is formed on the end of the mounting stem 67700 to engage the stop 67122 formed in the axial slot 67120 to limit the axial travel of the universally movable joint 60200″ in the direction PD.

The mounting member 67100 includes a shaft hole 67110 configured to permit various drive shafts and/or other instrument components to pass therethrough. In one non-limiting arrangement, each slot 67120 opens into the shaft hole 67110. FIG. 43 illustrates a portion of a shaft or conduit 67200 extending through the shaft hole 67110. In such arrangement, the shaft or conduit 67200 retains the mounting member 67700 and the stop block 67702 in the corresponding axial slot 67120. Depending on the axial length of the mounting stem or feature 67700, the mounting stem 67700 and stop block 67702 may move axially in the axial slot 67120 which facilities axial movement of the universally movable joint 60200″ relative to the mounting member 67100. In other arrangements, the mounting stems 67700 and stop blocks 67702 may be non-movably retained within their corresponding axial slots 67120 by welding, adhesive, or other suitable fastener means. Such arrangements facilitate easy assembly of the articulation joint components.

Returning now to the surgical stapling assembly 400 illustrated in FIGS. 12-14, as was discussed above, the surgical stapling assembly 400, in at least one form comprises an end effector 200 that is operably coupled to a shaft assembly 410 by an articulation joint 420. The end effector 200 comprises an anvil jaw 203 that is pivotally coupled to a cartridge jaw 201 and is moved between an open and closed position relative thereto by a closure drive that is configured to operably interface with the closure drive shaft segment 475. Additionally, the end effector 200 further comprises a firing member 270 that operably interfaces with the firing screw 261 such that as the firing screw 261 is rotated, the firing member 270 is advanced distally or retracted proximally along the firing screw 261. The firing screw 261 operably interfaces with the firing drive shaft segment 476 which serves to transmit rotary drive motions thereto from a firing drive. The firing drive may, for example, comprise any suitable source of rotary firing motions. For example, the firing drive may comprise a firing drive motor operably supported in a surgical instrument housing or portion of a robotic system.

In one non-limiting arrangement for example, the closure drive comprises a proximal closure drive shaft portion 68002 that extends through the outer shaft 411 of the shaft assembly 410 and operably interfaces with a source of rotary closure motions supported in or by the housing or robotic system. The closure drive may further comprise an intermediate closure drive shaft portion that bridges the articulation joint(s) and a distal closure drive shaft portion that is supported in the end effector 200. In one arrangement, the proximal portion may comprise a rigid shaft segment, a flexible shaft segment, or a combination of rigid and flexible segments, for example. In one non-limiting arrangement, the intermediate closure drive shaft portion may comprise one universally movable joint (60200) or a series of movable joints or universally movable drive shaft segment (60700) that spans the articulation joint(s). The distal closure drive shaft portion may comprise a closure drive shaft arrangement supported in the end effector to apply opening and closing motions to the anvil in the various manners disclosed herein.

Similarly, the firing drive may comprise a proximal firing shaft portion that extends through the outer shaft 411 of the shaft assembly 410 and operably interfaces with a source of rotary firing motions supported in or by the housing or robotic system. The firing drive may further comprise an intermediate firing drive shaft portion that bridges the articulation joint(s) and a distal firing drive shaft portion that is supported in the end effector 200. In one arrangement, the proximal firing drive shaft portion may comprise a rigid shaft segment, a flexible shaft segment, or a combination of rigid and flexible segments, for example. In one non-limiting arrangement, the intermediate firing drive shaft portion may comprise one universally movable joint (60200) or a series of movable joints or universally movable drive shaft segment (60700) that spans the articulation joint(s). The distal firing drive shaft portion may comprise a firing drive shaft arrangement supported in the end effector to apply drive motions to the firing member 270 in the various manners disclosed herein.

FIG. 44 illustrates a proximal closure drive shaft portion 68002, an intermediate closure drive shaft portion 68100, and a distal closure drive shaft portion 68300 employed in the surgical stapling assembly 400 described above. FIG. 44 also illustrates a proximal firing drive shaft portion 68004, an intermediate firing shaft portion 68500, and a distal firing shaft portion 68600.

FIG. 45 illustrates one example of an intermediate closure drive shaft portion 68100 in accordance with at least one aspect of the present disclosure. As can be seen in FIG. 45, a proximal closure drive shaft 68010 is attached to a closure coupler member 68110 for movement relative thereto. In at least one non-limiting arrangement, the closure coupler member 68110 is fabricated from a flexible material (polymer, rubber, etc.) that facilitates some torsional and axial flexure while remaining sufficiently rigid to effective transmit the rotary closure motions therethrough. For example, the closure coupler member 68110 comprises an elongate body 68112 that includes a proximal end 68114 and a distal end 68116 and a central portion 68118 that extends therebetween. The central portion 68118 has a central outer diameter that is less than an outer diameter of each of the proximal end 68114 and the distal end 68116 to facilitate axial flexing (arrow F).

The proximal closure drive shaft 68010 may comprise a rigid shaft segment, a flexible shaft segment (e.g., torsion cable, etc.) or a combination of rigid and flexible segments, for example. The proximal closure drive shaft 68010 may operably interface with a source of rotary closure motions (e.g., a motor, etc.) that is operably supported by or in a housing or portion of a robotic system, for example. In the illustrated arrangement, the proximal closure drive shaft 68010 comprises a bulbous distal end 68012 that is received in a proximal socket 68120 in the proximal end 68114 of the closure coupler member 68110. The bulbous distal end 68012 of the proximal closure drive shaft 68010 is pivotally coupled to the proximal end 68114 of the closure coupler member 68110 by a proximal closure pin 68130 that is received in an X-shaped passage 68014 in the bulbous distal end 68012 of the proximal closure drive shaft 68010. It will be appreciated that the X-shaped passage 68014 facilitates some pivotal travel between the proximal closure drive shaft 68010 and the closure coupler member 68110.

The closure coupler member 68110 is operably coupled to a distal closure drive shaft 68300 which comprises the closure drive shaft segment 475 depicted in FIG. 13 and includes a closure coupler shaft 68310 that operably interfaces with the closure screw 251 as will be discussed in further detail below. In at least one arrangement, the closure coupler shaft 68310 comprises a bulbous proximal end 68312 that is received in a distal socket 68122 of the closure coupler member 68110. The bulbous proximal end 68312 of the closure coupler shaft 68310 is pivotally coupled to the distal end 68116 of the closure coupler member 68110 by a distal closure pin 68132 that is received in an X-shaped passage 68314 in the bulbous proximal end 68312 of the closure coupler shaft 68310. It will be appreciated that the X-shaped passage 68314 facilitates some pivotal travel between the closure coupler shaft 68310 and the closure coupler member 68110.

As can be seen in FIG. 45, the intermediate closure drive shaft portion 68100 is housed within the articulation component support structure 440. In at least one arrangement, the articulation component support structure 440 is fabricated from a flexible material such as polymer, rubber, etc. and has an accordion-like shape to facilitate axial and bending flexure.

FIG. 46 illustrates one example of an intermediate firing drive shaft portion 68500 in accordance with at least one aspect of the present disclosure. As can be seen in FIG. 46, a proximal firing drive shaft 68020 is attached to a firing coupler member 68510 for movement relative thereto. In at least one non-limiting arrangement, the firing coupler member 68510 is fabricated from a flexible material (polymer, rubber, etc.) that facilitates some torsional flexure, bending flexure, and/or axial flexure while remaining sufficiently rigid to effective transmit the rotary closure motions therethrough. For example, the firing coupler member 68510 comprises an elongate body 68512 that includes a proximal end 68514 and a distal end 68516 and a central portion 68518 that extends therebetween. The central portion 68518 has a central outer diameter that is less than an outer diameter of each of the proximal end 68514 and the distal end 68516 to facilitate axial flexing (arrow F).

The proximal firing drive shaft 68020 may comprise a rigid shaft segment, a flexible shaft segment (e.g., torsion cable, etc.) or a combination of rigid and flexible segments, for example. The proximal firing drive shaft 68020 may operably interface with a source of rotary firing motions (e.g., a motor, etc.) that is operably supported by or in a housing or portion of a robotic system, for example. In the illustrated arrangement, the proximal firing drive shaft 68020 comprises a bulbous distal end 68022 that is received in a proximal socket 68520 in the proximal end 68514 of the firing coupler member 68510. The bulbous distal end 68022 of the proximal firing drive shaft 68020 is pivotally coupled to the proximal end 68514 of the firing coupler member 68510 by a proximal firing pin 68630 that is received in an X-shaped passage 68024 in the bulbous distal end 68022 of the proximal firing drive shaft 68020. It will be appreciated that the X-shaped passage 68024 facilitates some pivotal travel between the proximal firing drive shaft 68020 and the firing coupler member 68510.

The firing coupler member 68510 is operably coupled to a distal firing drive shaft portion 68600 which comprises the firing drive shaft segment 476 depicted in FIG. 13 and includes a firing coupler shaft 68610 that operably interfaces with the firing screw 261 as will be discussed in further detail below. In at least one arrangement, the firing coupler shaft 68610 comprises a bulbous proximal end 68612 that is received in a distal socket 68522 of the firing coupler member 68510. The bulbous proximal end 68612 of the firing coupler shaft 68610 is pivotally coupled to the distal end 68516 of the firing coupler member 68510 by a distal firing pin 68532 that is received in an X-shaped passage 68614 in the bulbous proximal end 68612 of the firing coupler shaft 68610. As can be seen in FIG. 46, the intermediate firing drive shaft portion 68500 is housed within the articulation component support structure 440. It will be appreciated that the X-shaped passage 68614 facilitates some pivotal travel between the firing coupler shaft 68610 and the firing coupler member 68510.

FIG. 47 comprises a longitudinally extending cross-sectional view of a proximal end portion of the end effector 200 illustrating the distal closure drive shaft portion 68300 and the distal firing drive shaft portion 68600. In the illustrated arrangement, the distal closure drive shaft portion 68300 comprises the closure screw 251 that is rotatably supported the cartridge channel 210 by a channel mounting fixture 68700 that is mounted within a proximal end of the cartridge channel 210. The channel mounting fixture 68700 facilitates rotation of the closure screw 251 while preventing axial movement thereof. The closure screw 251 comprises a series of closure drive threads that threadably interface with a threaded passage in the closure wedge 255. Rotation of the closure screw 251 in a first rotary direction will cause the closure wedge 255 to axially move in a first axial direction and rotation of the closure screw 251 in a second rotary direction opposite to the first rotary direction will cause the closure wedge 255 to axially move in a second axial direction. For example, rotation of the closure screw 251 in a first rotary direction may cause the closure wedge 255 to axially move in a distal direction DD to apply a closure motion to the anvil 203. Rotation of the closure screw 251 in a second rotary direction may cause the closure wedge 255 to axially move in a proximal direction to apply an opening motion to the anvil 203.

Still referring to FIG. 47, the closure screw 251 defines a distal closure shaft axis DC-DC and includes a proximal mounting flange 68712 and a closure coupler stem 68710 that protrudes proximally from the proximal mounting flange 68712 and is axially aligned on the distal closure shaft axis DC-DC. The closure coupler stem 68710 has a non-circular cross-sectional shape and is adapted to be movably and non-rotationally received in a coupler socket 68316 in a distal end of the closure coupler shaft 68310. In one non-limiting arrangement, as can be seen in FIG. 48, closure coupler stem 68710 has a square cross-sectional shape. Other arrangements may, for example, have a hexagonal cross-sectional shape. Coupler socket 68316 has a similar square shape and is configured to facilitate axial movement of the closure coupler shaft 68310 relative to the closure screw 251 while transmitting rotary closure motions (torque) thereto. Such slidable coupling arrangement may also avoid binding and stackup between the coupled drive portions. The proximal mounting flange 68712, as well as the coupler socket 68316, is freely rotatable in an opening 68714 in the second shaft joint component 450. A socket flange 68318 is provided on a distal end of the coupler socket 68316 which serves to limit the proximal travel of the coupler socket 68316 when the socket flange 68318 contacts an end of the opening 68714. The closure coupler stem 68710 is sized relative to the coupler socket 68316 such that when the coupler socket 68316 has reached the limit of its proximal travel, the closure coupler stem 68710 remains in operable engagement with the coupler socket 68316 to prevent the closure screw 251 from becoming disconnected from the closure coupler shaft 68310.

In the illustrated arrangement, the distal firing drive shaft portion 68600 comprises the firing screw 261 screw that is rotatably supported the cartridge channel 210 by the channel mounting fixture 68700. The channel mounting fixture 68700 facilitates rotation of the firing screw 261 while preventing axial movement thereof. The firing screw 261 comprises a series of closure drive threads that threadably interface with a threaded passage in a threaded drive nut that is configured to operably interface with the firing member 270 or a threaded passage in the firing member 270 itself. Rotation of the firing screw 261 in a first rotary direction will cause the firing member 270 to axially move in a first axial direction and rotation of the firing screw 261 in a second rotary direction opposite to the first rotary direction will cause the firing member 270 to axially move in a second axial direction. For example, rotation of the firing screw 261 in a first rotary direction may cause the firing member 270 to axially move in a distal direction DD and rotation of the firing screw 261 in a second rotary direction may cause the firing member 270 to axially move in a proximal direction PD.

Still referring to FIG. 47, the firing screw 261 defines a distal firing shaft axis DF-DF and includes a proximal mounting flange 68722 and a firing coupler stem 68720 that protrudes proximally from the proximal mounting flange 68722 and is axially aligned on the distal firing shaft axis DF-DF. The firing coupler stem 68720 has a non-circular cross-sectional shape and is adapted to be movably and non-rotationally received in a coupler socket 68616 in a distal end of the firing coupler shaft 68610. In one non-limiting arrangement, the firing coupler stem 68720 has a square cross-sectional shape. Other arrangements may, for example, have a hexagonal cross-sectional shape. Coupler socket 68616 has a similar square shape and is configured to facilitate axial movement of the firing coupler shaft 68610 relative to the firing screw 261 while transmitting rotary (torque) firing motions thereto. Such slidable coupling arrangement may also avoid binding and stackup between the coupled drive portions.

The proximal mounting flange 68722 as well as the coupler socket 68616, are freely rotatable in an opening 68724 defined in the cartridge channel 210 and the channel mounting fixture 68700. A socket flange 68618 is provided on a distal end of the coupler socket 68616 which serves to limit the proximal travel of the coupler socket 68616 when the socket flange 68618 contacts an end of the opening 68724. The firing coupler stem 68720 is sized relative to the coupler socket 68616 such that when the coupler socket 68616 has reached the limit of its proximal travel, the firing coupler stem 68720 remains in operable engagement with the coupler socket 68616 to prevent the firing screw 261 from becoming disconnected from the firing coupler shaft 68610.

FIG. 49 illustrates intermediate closure drive shaft portion 69100 and an intermediate firing drive shaft portion 69500 employed in the surgical stapling assembly 500 described above. The intermediate closure drive shaft portion 69100 is configured to be operably attached to a distal closure drive shaft portion 68300′ which may comprise the closure drive shaft segment 575 depicted in FIG. 16 and is substantially similar to the distal closure drive shaft portion 68300 described above. In this embodiment, the intermediate closure drive shaft portion 69100 includes closure coupler member 69110 that comprises a solid cylindrical body that is coupled to the proximal closure drive shaft portion 68002 and the distal closure drive shaft portion 68300′ in the manners described above. In at least one non-limiting arrangement, the closure coupler member 69110 is fabricated from a flexible material (polymer, rubber, etc.) that facilitates some torsional and axial flexure while remaining sufficiently rigid to effective transmit the rotary closure motions therethrough. Similarly, the intermediate firing drive shaft portion 69500 is configured to be operably attached to a distal firing drive shaft portion 68600′ which comprises the firing drive shaft 576 depicted in FIG. 16 and is substantially similar to the distal firing drive shaft portion 68600 described above. In this embodiment, the intermediate firing drive shaft portion 69500 includes firing coupler member 69510 that comprises a solid cylindrical body that is coupled to the proximal firing drive shaft portion 68004 in the manners described above. In at least one non-limiting arrangement, the firing coupler member 69510 is fabricated from a flexible material (polymer, rubber, etc.) that facilitates some torsional and axial flexure while remaining sufficiently rigid to effective transmit the rotary closure motions therethrough.

The closure and drive shaft arrangements depicted in FIGS. 44-49 comprise dual rotary drive systems wherein the first (distal) portions are prevent from moving axially and the second portions (intermediate) portion is slidably coupled thereto. Each rotary drive comprises three portions: a proximal portion located in the shaft assembly, a distal portion located in the end effector, and an intermediate portion that bridges the articulation joint(s). The intermediate portion could comprise one or more universally movable joints or a torsion cable coupling. The distal portion is fixed longitudinally to the end effector and the proximal portion is fixed to a retainer in the shaft to prevent either of those portions from moving longitudinally or axially, for example. The intermediate portion may be slidably coupled to either one or both of the proximal and distal portions. The sliding coupling could be coupled to either or both ends of the distal portion and proximal portion or it may comprise a separate sliding aspect. These arrangements allow the intermediate portion to become effectively longer or shorter as the articulation joint(s) go through the range of motion. The sliding coupling of the intermediate portion to the distal portion and/or the proximal portion could be fixed within a chamber that allows the distal end/or proximal portion to slide but limits the maximum sliding distance. This prevents the drive from becoming separated if the articulation joint becomes hyperextended. The sliding couple is a square or hexagonal geometry that facilitates torque transmission but allows for allows for longitudinal sliding of the coupled drives. The dual intermediate portions are also supported by the articulation joint support structures that bridge the articulation joint. The coupling structures of the articulation joints allow for fixed-floating, fixed-fixed (but bendable), fixed-sliding, and/or sliding-sliding coupling of components.

FIG. 50 illustrates the end effector 200 and articulation region 110 described above (FIGS. 1-6) in cross-section. As described above, the flexible drive segments 175, 176 each consist of universally movable joints arranged or formed “end-to-end”. For example, the drive segments 175, 176 may each comprise a plurality of universally movable joints 60200 arranged end-to-end or the drive segments 175, 176 may comprise a universally movable drive shaft segment 60700 that was manufactured utilizing the additive manufacturing systems and processes described and contemplated herein. In one non-limiting arrangement for example, the closure drive 250 comprises a proximal closure drive shaft portion 69200 that extends through the outer shaft 411 of the shaft assembly 410 and operably interfaces with a source of rotary closure motions supported in or by the housing or robotic system (not shown). The proximal closure drive shaft portion 69200 may comprise, for example, a torsion cable 69202, a laser cut flexible shaft or other flexible rotary drive member, a rigid rotary drive member or a combination of a rigid rotary drive member(s) and a flexible rotary drive member(s). As can be seen in FIG. 50, the proximal closure drive shaft portion 69200 is coupled to an intermediate closure drive shaft portion 69300 that bridges both of the articulation joints in the articulation joint region 110 that comprises the flexible drive shaft segment 175. The flexible drive shaft segment 175 is coupled to a distal closure drive shaft portion 69400 that comprises a closure drive shaft arrangement that is supported in the end effector to apply opening and closing motions to the anvil in the various manners disclosed herein.

Still referring to FIG. 50, in one non-limiting form, the distal closure drive shaft portion 69400 comprises a closure coupler shaft 69410 that operably interfaces with the closure screw 251 in the manner described herein. In at least one arrangement, the closure coupler shaft 69410 is integrally formed with the flexible drive shaft segment such that the closure coupler shaft 69410 is printed with the flexible drive shaft segment 175 utilizing the additive manufacturing systems and processes described and contemplated herein. In other arrangements, the closure coupler shaft 69410 is otherwise attached to a distal-most universally movable joint member 60200D in the flexible drive shaft segment 175 by welding, adhesive, threads, etc.

As discussed above, the closure screw 251 includes a proximal mounting flange 68712 and a closure coupler stem 68710 that protrudes proximally from the proximal mounting flange 68712. The closure coupler stem 68710 has a non-circular cross-sectional shape and is adapted to be movably and non-rotationally received in a coupler socket 69416 in a distal end of the closure coupler shaft 69410. The closure coupler stem 68710 has a square cross-sectional shape. Other arrangements may, for example, have a hexagonal cross-sectional shape. Coupler socket 68316 has a similar square shape and is configured to facilitate axial movement of the closure coupler shaft 69410 relative to the closure screw 251 while transmitting rotary closure motions (torque) thereto. Such slidable coupling arrangement may also avoid binding and stackup between the coupled drive portions. The proximal mounting flange 68712, as well as the coupler socket 69416, is freely rotatable in an opening 68714 in the second shaft joint component 450.

In one aspect, the firing drive comprises a proximal firing drive shaft portion 69500 that extends through the outer shaft 411 of the shaft assembly 410 and operably interfaces with a source of rotary firing motions that is supported in or by the housing or robotic system. The proximal firing drive shaft portion 69500 may comprise, for example, another torsion cable 69502, laser-cut flexible shaft or another flexible rotary drive member, another rigid rotary drive member or a combination of another rigid rotary drive member and another flexible rotary drive member. As can be seen in FIG. 50, the proximal firing drive shaft portion 69500 is coupled to an intermediate firing drive shaft portion 69600 that bridges both of the articulation joints in the articulation joint region 110 that comprises the flexible drive shaft segment 176. The flexible drive shaft segment 176 is coupled to a distal firing drive shaft portion 69700 that comprises a firing drive shaft arrangement supported in the end effector to apply firing drive motions to the firing member 270 in the various manners disclosed herein.

Still referring to FIG. 50, in one non-limiting form, the distal firing drive shaft portion 69700 comprises the flexible drive shaft segment 176 and includes a firing coupler shaft 69710 that operably interfaces with the firing screw 261 as was described above. In at least one arrangement, the firing coupler shaft 69710 is integrally formed with the flexible drive shaft segment 176 such that the firing coupler shaft 69710 is printed with the flexible drive shaft segment 176 utilizing the additive manufacturing systems and processes described and contemplated herein. In other arrangements, the firing coupler shaft 69710 is otherwise attached to a distal-most universally movable joint member 60200DF in the flexible drive shaft segment 176 by welding, adhesive, threads, etc.

In the illustrated arrangement, the distal firing drive shaft portion 69700 comprises the firing screw 261 that is rotatably supported the cartridge channel 210 by the channel mounting fixture 68700. The channel mounting fixture 68700 facilitates rotation of the firing screw 261 while preventing axial movement thereof. The firing screw 261 comprises a series of closure drive threads that threadably interface with a threaded passage in a threaded drive nut configured to operably interface with the firing member 270 or a threaded passage in the firing member 270 itself. Rotation of the firing screw 261 in a first rotary direction will cause the firing member 270 to axially move in a first axial direction and rotation of the firing screw 261 in a second rotary direction opposite to the first rotary direction will cause the firing member 270 to axially move in a second axial direction.

Still referring to FIG. 50, the firing screw 261 includes a firing coupler stem 68720 that protrudes proximally. The firing coupler stem 68720 has a non-circular cross-sectional shape and is adapted to be movably and non-rotationally received in a coupler socket 69716 in a distal end of the firing coupler shaft 69710. In one non-limiting arrangement, the firing coupler stem 68720 has a square cross-sectional shape. Other arrangements may, for example, have a hexagonal cross-sectional shape. Coupler socket 69716 has a similar square shape and is configured to facilitate axial movement of the firing coupler shaft 69710 relative to the firing screw 261 while transmitting rotary (torque) firing motions thereto. Such slidable coupling arrangement may also avoid binding and stackup between the coupled drive portions. Thus, rotation of the proximal closure shaft portion 69200 in a first rotary direction will drive the closure wedge 255 distally to move the anvil jaw 203 to pivot to the closed position shown in FIG. 50. Rotation of the proximal closure shaft portion 69200 in an opposite rotary direction will drive the closure wedge 255 proximally to pivot the anvil jaw 203 into an open position. After the anvil jaw 203 has been moved to the closed position to clamp target tissue between the anvil jaw 203 and the staple cartridge 220, rotation of the proximal firing shaft portion 69500 in a first direction will cause the firing member 270 to move distally within the staple cartridge 220 to drive the staples therefrom and cut through the clamped tissue in the manner described herein. Rotation of the proximal firing shaft portion 69500 in an opposite rotary direction will cause the firing member 270 to move proximally back to a starting position in which the anvil jaw 203 may be moved to the open position to release the cut and stapled tissue.

FIGS. 51-53 illustrate a portion of a surgical stapling instrument 10′ that is substantially similar to the surgical stapling instrument 10 described above, except for the differences described in detail below. In particular, instead of the flexible drive shaft segments 175, 176 that are formed from universally movable joints, the surgical stapling instrument employs a closure drive 250′ comprises flexible closure drive shaft 69210 that extends through the outer shaft 101 of the shaft assembly 100 and operably interfaces with a source of rotary closure motions that is supported in or by the housing or robotic system (not shown). The flexible closure drive shaft 69210 may comprise, for example, a torsion cable, a laser cut flexible shaft or other flexible rotary drive member, a rigid rotary drive member or a combination of a rigid rotary drive member(s) (portion(s) inside the outer shaft 101) and a flexible rotary drive member(s) (portion(s) that spans the articulation region 110). As can be seen in FIG. 53, the flexible closure drive shaft 69210 is coupled to the closure screw 251 to apply rotary closure motions thereto to open and close the anvil jaw 203 in the manners described herein.

As can be further seen in FIGS. 52 and 53, the firing drive 260′ comprises a flexible firing drive shaft 69520 that extends through the outer shaft 101 of the shaft assembly 100 and operably interfaces with a source of rotary firing motions supported in or by the housing or robotic system (not shown). The flexible firing drive shaft 69520 may comprise, for example, a torsion cable, a laser cut flexible shaft or other flexible rotary drive member, a rigid rotary drive member or a combination of a rigid rotary drive member (portion inside the outer shaft 101) and a flexible rotary drive member (portion that spans the articulation region 110). As can be seen in FIG. 53, the flexible firing drive shaft 69520 is coupled to the firing screw 261 to apply rotary firing motions thereto to move the firing member 270 through the end effector 200 in the manners described herein. In this arrangement, the portions of the flexible closure drive shaft 69210 and the flexible firing drive shaft 69520 that span the articulation region 110 are supported in a flexible shaft guide 69000.

FIGS. 54-62 illustrate one form of a shaft guide 69000 that may be employed in connection with the shaft assembly 100. In the illustrated example, the shaft guide 69000 comprises a shaft guide body 69010 that is sized to space across the articulation region 110. The shaft guide body 69010 comprises a shaft guide proximal end 69020 and a shaft guide distal end 69030 and defines a shaft guide axis SGA that extends between the shaft guide proximal end 69020 and the shaft guide distal end 69030. The shaft guide body 69010 further comprises a first passage 69022 that extends through the shaft guide body 69010 from the shaft guide proximal end 69020 to the shaft guide distal end 69030. In the illustrated example, the first passage 69022 opens through the shaft guide proximal end 69020 on a first side FRP₁ of a first reference plane FRP-FRP (FIG. 55) and opens through the shaft guide distal end 69030 on a first side SRP₁ of a second reference plane SRP (FIG. 56). In the illustrated arrangement, a central portion 69024 of the first passage 69022 at least partially passes through one or both of the first reference plane FRP and the second reference plane SRP.

Still referring to FIGS. 55 and 56, the shaft guide body 69010 further comprises a second passage that extends through the shaft guide body 69010 from the shaft guide proximal end 69020 to the shaft guide distal end 69030. The second passage 69026 opens through the shaft guide proximal end 69020 on a second side FRP₂ of the first reference plane FRP (FIG. 55) and opens through the shaft guide distal end 69030 on a second side SRP2 of the second reference plane SRP (FIG. 56). In the illustrated arrangement, a central portion 69028 of the second passage 69026 at least partially passes through one or both of the first reference plane FRP and the second reference plane SRP. As can be seen in FIG. 55, a proximal end 69023 of the first passage 69022 is bisected by the second reference plane SRP and a proximal end 69027 of the second passage 69026 is also bisected by the second reference plane SRP. As can be seen in FIG. 56, a distal end 69025 of the first passage 69022 is bisected by the first reference plane FRP and a distal end 69029 of the second passage 69026 is bisected by eth first reference plane FRP.

In at least one arrangement, the shaft guide 69000 is fabricated from a bendable elastic or ductile material (e.g., polypropylene, low density polyethylene, liquid crystal polymer (LCP), Nylon, etc.) that facilitates twisting flexure of the shaft guide 69000 when the end effector 200 is articulated about at least one of the first articulation axis AA1-AA1 and the second articulation axis AA2-AA2. The shaft guide body 69010 comprises a central body portion 69012 that extends between the shaft guide proximal end 69020 and the shaft guide distal end 69030. In at least one non-limiting example, the central body portion 69012 comprises central bulbous portion 69014 which may further facilitate such flexure during articulation. Further, in at least one arrangement, the shaft guide body 69010 comprises a proximal necked down portion 69016 that is located between the central bulbous portion 69014 and the shaft guide proximal end 69020 and which essentially coincides with the first articulation axis AA1-AA1. The proximal necked down portion 69016 may be formed by a first pair of opposed proximal scallops 69017 that correspond to the first articulation axis AA1-AA1. See FIG. 54. The shaft guide body 69010 may further comprise a distal necked down portion 69018 that is located between the central bulbous portion 69014 and the shaft guide distal end 69030 and which essentially coincides with the second articulation axis AA2-AA2. The distal necked down portion 69018 may be formed by a second pair of opposed distal scallops 69019 that correspond to the second articulation axis AA2-AA2. Such “necked-down” or “reduced diameter” segments further facilitate flexure of the shaft guide 69000 during articulation of the end effector 200.

As can be seen in FIG. 55, in at least one arrangement, the shaft guide proximal end 69020 comprises an oval or egg shape that is aligned on a proximal long axis PLA that is aligned with the second reference plane SRP. Likewise, as can be seen in FIG. 56, the shaft guide distal end 69030 comprises an oval or egg shape that is aligned on a distal long axis DLA-DLA that is aligned with the first reference plane FRP.

As can be seen in FIG. 53, the shaft guide 69000 spans the articulation region 110 and the shaft guide distal end 69030 is supported in and/or coupled to the distal shaft feature 140 and the shaft guide proximal end 69020 is supported in and/or attached to the proximal shaft feature 120. In the illustrated arrangement, the flexible drive shaft segment 175 is received within the first passage 69022 and the flexible drive shaft segment 176 is received within the second passage 69026. The shaft guide proximal end 69020 is coupled to a portion of the proximal shaft feature 120 and the shaft guide distal end 69030 is coupled to the distal shaft feature 140. The flexible drive shaft segment 175 operably extends through the first passage 69022 and the flexible drive shaft segment 176 extends through the second passage 69026. In the illustrated example, the proximal closure drive shaft portion 69200 extends through the outer shaft 101 of the shaft assembly 100 and is located on one lateral side of the shaft guide axis SGA to be coupled to the intermediate closure drive shaft portion 69300 (flexible drive shaft segment 175) supported in the first passage 69022 in the shaft guide 69000. Likewise, the proximal firing drive shaft portion 69500 extends through the outer shaft 101 of the shaft assembly 100 and is located on another lateral side of the shaft guide axis SGA to be coupled to the intermediate firing drive shaft portion 69600 (flexible drive shaft segment 176) that is supported in the second passage 69026 in the shaft guide 69000. Thus, when the intermediate closure drive shaft portion 69300 and the intermediate firing drive shaft portion 69600 enter the shaft guide proximal end 69020, the intermediate closure drive shaft portion 69300 and the intermediate firing drive shaft portion 69600 are in a side-by-side relationship or configuration (one on each side of the shaft guide axis SGA). When the intermediate closure drive shaft portion 69300 and the intermediate firing drive shaft portion 69600 exit the shaft guide distal end in a vertically stacked relationship wherein the intermediate closure drive shaft portion 69300 is above the intermediate firing drive shaft portion 69600.

In one instance, the first passage 69022 and the second passage 69026 twist as they go from the shaft guide proximal end 69020 to the shaft guide distal end 69030. The shaft guide 69000 comprises a support for the intermediate closure drive shaft portion 69300 and the intermediate firing drive shaft portion 69600 that avoids forming a preferred bend plane. The shaft guide 69000 spans two, in-series articulation joints of a multi-axis joint arrangement without forming a preferred bending orientation. In at least one arrangement, the multi-axis joint arrangement facilitates articulation of the end effector through two articulation angles about articulation axes AA1-AA1, AA2-AA2, that are each at least approximately 75 degrees in magnitude. The exterior profile of the shaft guide 69000 as well as each of the first passage 69022 and the second passage 69026 can twist to minimize its bending resistance by aligning its minimum moment of inertia plane to that of the articulation axes. In alternative arrangements, each of the first passage 69022 and the second passage 69026 may twist multiple times between the shaft guide proximal end 69020 and the shaft guide distal end 69030. In such instances, for example, each of the first passage 69022 and the second passage 69026 may pass through each of the first reference plane FRP and the second reference plane SRP multiple times.

In accordance with at least one aspect of the present disclosure, the proximal end 69027 of the second passage 69026 opens through the shaft guide proximal end 69020 in a “first orientation” relative to the proximal end 69023 of the first passage 69022. In the example illustrated in FIG. 55, the proximal end 69027 of the second passage 69026 is horizontally spaced from or “horizontally aligned” with the proximal end 69023 of the first passage 69022. Other first orientations are contemplated. Also in accordance with at least one aspect of the present disclosure, the distal end 69029 of the second passage 69026 is oriented in a “second orientation” relative to the distal end 69025 of the first passage 69022 that differs from the first orientation. For example, as can be seen in FIG. 56, the second passage distal end 69029 is located below the first passage distal end 69025. Stated another way the first passage distal end 69025 and the second passage distal end 69029 are “vertically stacked” with each other or “vertically aligned” with each other. Other second orientations are contemplated. In still other applications, the shaft guide 69000 may be installed in a reversed orientation between the surgical end effector and the shaft assembly so that the shaft guide proximal end 69020 will actually be distal to the shaft guide distal end 69030. Thus, in such arrangement, the drive shafts entering the shaft guide 69000 will be vertically stacked relative to each other and they will exit the shaft guide 69000 in a horizontally spaced orientation, for example.

FIG. 63 illustrates a portion of another surgical stapling instrument 70010 that comprises an elongate shaft assembly 100 that may be operably coupled to a housing of a surgical instrument or portion of a robotic system of the various types and forms described and contemplated herein. The elongate shaft assembly 100 is operably coupled to an end effector 200 by an articulation joint assembly 71000. The end effector 200 may comprise a variety of different end effectors configured to perform a particular surgical function. In the illustrated arrangement, the end effector 200 is configured to clamp, staple, and cut tissue of a patient. However, other forms of end effectors may be employed. In this example, the end effector 200 comprises a cartridge jaw 201 and an anvil jaw 203. The anvil jaw 203 is pivotable relative to the cartridge jaw 203 to clamp tissue between the anvil jaw 203 and the cartridge jaw 201. Once tissue is clamped between the jaws 201, 203, the surgical stapling instrument 70010 may be actuated to advance a firing member through the jaws 201, 203 to staple and cut tissue with the end effector 200 as discussed in greater detail below.

To open and close the anvil jaw 203 relative to the cartridge jaw 201, a closure drive 250 is provided. See FIG. 64. The closure drive 250 is actuated by a flexible closure drive shaft 72000 that may comprise a flexible shaft segment (e.g., torsion cable, laser cut shaft, etc.) or a combination of rigid segment(s) and flexible segment(s), for example that operably interface with a source of rotary closure motions supported in or by the housing or robotic system. Discussed in greater detail below, the flexible closure drive shaft 72000 is driven by a closure input shaft 72010 that extends through the shaft assembly 100 and operably interfaces with a source of rotary closure motions (e.g., a motor) supported in a housing of the surgical instrument or portion of a robotic system. The flexible closure drive shaft 72000 transmits rotary actuation motions through the articulation joint assembly 71000. The closure drive 250 comprises a closure screw 251 and a closure wedge 255 that is threadably coupled to the closure screw 251. The closure wedge 255 is configured to positively cam the anvil jaw 203 open and closed in the various manners described herein. The closure screw 251 is supported by a first support body 258 and a second support body 259 secured within the channel 210. See FIG. 64.

To move the anvil jaw 203 between a clamped position and an unclamped position, the closure input shaft 72010 is actuated (rotated) to actuate (rotate) the flexible closure drive shaft 72000. The flexible closure drive shaft 72000 is coupled to the closure screw 251 by a coupler 72012 and is configured to rotate the closure screw 251, which displaces the closure wedge 255. For example, the closure wedge 255 is threadably coupled to the closure screw 251 and rotational travel of the closure wedge 255 with the staple cartridge 220 is restrained. The closure screw 251 drives the closure wedge 255 proximally or distally depending on which direction the closure screw 251 is rotated.

As discussed above, the surgical stapling instrument 70010 may be actuated to advance a firing member through the jaws 201, 203 to staple and cut tissue with the end effector 200. As was discussed above, staples that are stored in the staple cartridge 220 are deployed when a sled (not shown in FIG. 64) is driven distally through the staple cartridge 220. A knife (not shown) is operably supported on the sled and serves to cut tissue clamped between the anvil 203 and the cartridge 220 as the sled is driven distally through the staple cartridge 220 by a firing member 270. The firing member 270 is driven distally through the end effector 200 by a firing drive 260. The firing drive 260 is actuated by a flexible firing drive shaft 72100. The flexible firing drive shaft 72100 comprises a flexible shaft segment (e.g., torsion cable, laser cut flexible shaft, etc.) or a combination of rigid and flexible segments, for example, that operably interface with a source of rotary firing motions (e.g., firing drive motor) that is supported in or by the housing of the surgical instrument or robotic system. The flexible firing drive shaft 72100 is driven by a firing input shaft 72110 that extends through the shaft assembly 100. The flexible firing drive shaft 72100 transmits rotary actuation motions through the articulation joint assembly 71000 to a firing screw 261 that comprises a portion of the firing drive 260. The firing screw 261 comprises journals supported within bearings in the support member 259 and the channel 210. The firing screw 261 comprises a proximal end 262 supported within the support member 259 and the channel 210, a distal end 263 supported within the channel 210, and threads 265 extending along a portion of the length of the firing screw 261.

The firing member 270 is threadably coupled to the firing screw 261 such that as the firing screw 261 is rotated, the firing member 270 is advanced distally or retracted proximally along the firing screw 261. Specifically, the firing member 270 comprises a body portion 271 comprising a hollow passage 272 defined therein. The firing screw 261 is configured to be received within the hollow passage 272 and is configured to be threadably coupled with a threaded component 273 of the firing member 270. Thus, as the firing screw 261 is rotated, the threaded component 273 applies a linear force to the body portion 271 to advance the firing member 270 distally or retract the firing member 270 proximally. As the firing member 270 is advanced distally, the firing member 270 pushes the sled (not shown) that is movable supported in the staple cartridge 220. Distal movement of the sled causes the ejection of the staples by engaging the plurality of staple drivers, as described above. The flexible firing drive shaft 72100 is coupled to the firing screw 261 by a coupler 72112 and is configured to rotate the firing screw 251, which displaces the firing member 270.

Still referring to FIG. 64, one form of the articulation joint assembly 71000 comprises a proximal mounting member 71100 that is configured to interface with the shaft assembly 100 of the surgical stapling instrument 70010. For example, the proximal mounting member 71100 may be welded or attached to a distal portion of the shaft assembly 100 by any suitable means. In other arrangements, the proximal mounting member 71100 may comprise a portion of the shaft assembly 100. The articulation joint assembly 71000 further comprises a distal joint shaft component or distal mounting member 71300. The distal mounting member 71300 may be welded or attached to a proximal portion of the surgical end effector 200 by any suitable means. In the illustrated arrangement for example, the distal mounting member 71300 is attached to the proximal end of the cartridge jaw 201 by a retention ring 146. In other arrangements, the distal mounting member 71300 may comprise a portion of the surgical end effector 200.

In the non-limiting example illustrated in FIGS. 63 and 64, the proximal mounting member 71100 comprises a proximal shaft hole 71110 that is axially aligned on a shaft axis SA-SA that is defined by the shaft assembly 100. See FIG. 69. Similarly, the distal mounting member 71300 comprises a distal shaft hole 71310. The distal shaft hole 71310 may have a diameter that is the same or similar to a diameter of the proximal shaft hole 71110. When the surgical end effector 200 is aligned on the shaft axis SA-SA with the shaft assembly 100, the distal shaft hole 71310 is aligned with the proximal shaft hole 71110.

Referring now to FIGS. 65-69, in at least one non-limiting example, the articulation joint assembly 71000 further comprises a linkage assembly 71400 that is coupled to and extends between the proximal mounting member 71100 and the distal mounting member 71300. In at least one form, the linkage assembly 71400 comprises a plurality of articulation link members that extend between the proximal mounting member 71100 and the distal mounting member 71300 and are attached thereto. The illustrated non-limiting example comprises three articulation link members 71500A, 71500B and 71500C. Other numbers of articulation link members are contemplated. For example, a linkage assembly that only comprises two link members will work, but such linkage assembly may only facilitate articulation through a single plane.

In one non-limiting arrangement, articulation link member 71500A comprises a proximal link end 71510A, a link distal link end 71520A, and a link body 71530A. The proximal link end 71510A is coupled to the proximal mounting member 71100 at a first proximal attachment location 71120A by a first proximal joint assembly 71130A. In the illustrated example, the first proximal joint assembly 71130A comprises a pair of first proximal attachment lugs 71132A that protrude from the proximal mounting member 71100. A first proximal attachment link 71134A is pivotally coupled to the first proximal attachment lugs 71132A by a first proximal joint pin 71136A that defines a first proximal joint axis FPJA₁. The first proximal attachment link 71134A is pivotally attached to the proximal link end 71510A by a second proximal joint pin 71138A that defines a second proximal joint axis SPJA₂ that is transverse to the first proximal joint axis FPJA₁ as well as the shaft axis SA-SA.

In the illustrated example, the distal link end 71520A is coupled to the distal mounting member 71300 at a first distal attachment location 71320A by a first distal joint assembly 71330A. In the illustrated example, the first distal joint assembly 71330A comprises a pair of first distal attachment lugs 71332A that protrude from the distal mounting member 71300. A first distal attachment link 71334A is pivotally coupled to the first distal attachment lugs 71332A by a first distal joint pin 71336A that defines a first distal joint axis FDJA₁. The first distal attachment link 711334A is pivotally attached to the distal link end 71520A by a second distal joint pin 71338A that defines a second distal joint axis SDJA₂ that is transverse to the first distal joint axis FDJA₁ as well as the shaft axis SA-SA.

In one non-limiting arrangement, articulation link member 71500B comprises a proximal link end 71510B, a link distal link end 71520B, and a link body 71530B. The proximal link end 71510B is coupled to the proximal mounting member 71100 at a second proximal attachment location 71120B by a second proximal joint assembly 71130B. In the illustrated example, the second proximal joint assembly 71130B comprises a pair of second proximal attachment lugs 71132B that protrude from the proximal mounting member 71100. A second proximal attachment link 71134B is pivotally coupled to the second proximal attachment lugs 71132B by a first proximal joint pin 71136B that defines a third proximal joint axis TPJA₃. The second proximal attachment link 71134B is pivotally attached to the proximal link end 71510B by a second proximal joint pin 71138B that defines a fourth proximal joint axis FPJA₄ that is transverse to the third proximal joint axis TPJA₃ as well as the shaft axis SA-SA.

In the illustrated example, the distal link end 71520B is coupled to the distal mounting member 71300 at a second distal attachment location 71320B by a second distal joint assembly 71330B. In the illustrated example, the second distal joint assembly 71330B comprises a pair of second distal attachment lugs 71332B that protrude from the distal mounting member 71300. A second distal attachment link 71334B is pivotally coupled to the second distal attachment lugs 71332B by a first distal joint pin 71336B that defines a third distal joint axis TDJA₃. The second distal attachment link 71334B is pivotally attached to the distal link end 71520B by a second distal joint pin 71338B that defines a fourth distal joint axis FDJA₄ that is transverse to the third distal joint axis TDJA₃ as well as the shaft axis SA-SA.

In one non-limiting arrangement, articulation link member 71500C comprises a proximal link end 71510C, a link distal link end 71520C, and a link body 71530C. The proximal link end 71510C is coupled to the proximal mounting member 71100 at a third proximal attachment location 71120C by a third proximal joint assembly 71130C. In the illustrated example, the third proximal joint assembly 71130C comprises a pair of third proximal attachment lugs 71132C that protrude from the proximal mounting member 71100. A third proximal attachment link 71134C is pivotally coupled to the third proximal attachment lugs 71132C by a first proximal joint pin 71136C that defines a fifth proximal joint axis FPJA₅. The third proximal attachment link 71134C is pivotally attached to the proximal link end 71510C by a second proximal joint pin 71138C that defines a sixth proximal joint axis SPJA₆ that is transverse to the fifth proximal joint axis TPJA₅ as well as the shaft axis SA-SA. In one non-limiting example, the first proximal attachment location 71120A, the second proximal attachment location 71120B, and the third proximal attachment location 71120C are equally spaced about the shaft axis SA-SA. Stated another way, the angles between the first proximal attachment location 71120A, the second proximal attachment location 71120B, and the third proximal attachment location 71120C are each approximately 120°.

In the illustrated example, the distal link end 71520C is coupled to the distal mounting member 71300 at a third distal attachment location 71320C by a third distal joint assembly 71330C. In the illustrated example, the third distal joint assembly 71330C comprises a pair of third distal attachment lugs 71332C that protrude from the distal mounting member 71300. A third distal attachment link 71334C is pivotally coupled to the third distal attachment lugs 71332C by a first distal joint pin 71336C that defines a fifth distal joint axis FDJA₃. The third distal attachment link 71334C is pivotally attached to the distal link end 71520C by a second distal joint pin 71338C that defines a sixth distal joint axis SDJA₆ that is transverse to the fifth distal joint axis FDJA₅ as well as the shaft axis SA-SA. In one non-limiting example, the first distal attachment location 71320A, the second distal attachment location 71320B, and the third distal attachment location 71320C are equally spaced about the shaft axis SA-SA. Stated another way, the angles between the first distal attachment location 71320A, the second distal attachment location 71320B, and the third distal attachment location 71320C are each approximately 120°. In one arrangement, when the surgical end effector 200 is in an unarticulated position or, stated another way, axially aligned with the shaft assembly 100 on the shaft axis SA-SA, the first distal attachment location 71320A is diametrically opposite to the first proximal attachment location 71120A; the second distal attachment location 71320B is diametrically opposite to the second proximal attachment location 71120B; and the third distal attachment location 71320C is diametrically opposite to the third proximal attachment location 71120C.

In one aspect, the proximal shaft hole 71110 in the proximal mounting member 71100 and the distal shaft hole 71310 serve to define a central open passage area 72900. FIG. 70 illustrates an end view of articulation link member 71500A. As can be seen in FIG. 70, the link body 71530A comprises a curved surface 71532A that curves around the central open passage area 79200. The link body 72530B similarly has a curve surface 71532B and the link body 71530C has a curved surface 71532C. The curved surfaces 71532A, 71532B, 7532C cooperate to maintain the central open passage area 72900 regardless of the articulated position of the articulation joint assembly 71000. See e.g., FIGS. 66-67. It will be further appreciated that the length of the articulation joint assembly 71000 remains relatively constant during such articulation motions/positions. Stated another way, the distance DA between the proximal mounting member 71100 and the distal mounting member 71300 remains the same regardless of the articulation angle. Such range of articulation is facilitated because each of the link members 71500A, 71500B, 71500C may move (rotate) through a link path LP of approximately 180 degrees, for example. See FIG. 70.

FIG. 71 illustrates one form of a shaft guide 73000 that is configured to extend between the proximal mounting member 71100 and the distal mounting member 71300 while supporting the flexible closure drive shaft 72000 and the flexible firing drive shaft 72100 therein. In one aspect, the shaft guide 73000 comprises a shaft guide proximal end 73010, a shaft guide distal end 73020, and a central body portion 73030. The shaft guide proximal end 73010 comprises a proximal mounting collar 73012 that is configured to be rotatably supported within the proximal shaft hole 71110 in the proximal mounting member 71100. Similarly, the shaft guide distal end 73020 comprises a distal mounting collar 73022 that is configured to be rotatably supported in the distal shaft hole 71310 in the distal mounting member 71300. Such arrangement facilitates rotation of the shaft guide 73000 relative to the proximal mounting member 71100 and the distal mounting member 71300 while remaining affixed thereto. In another arrangement, the proximal mounting collar 73012 may additionally be configured relative to the proximal mounting member 71100 to facilitate some axial movement relative thereto as well. In addition to or in the alternative, the distal mounting collar 73022 may be configured to facilitate some axial movement relative to the distal mounting member 71300.

In one arrangement, the entire central body portion 73030 is flexible and may be fabricated from a ductile material (e.g., polypropylene, low density polyethylene, liquid crystal polymer (LCP), Nylon, etc.) that is configured to facilitate twisting flexure when the end effector is articulated. In another arrangement, for example, the central body portion 73030 comprises a relative rigid hollow center segment that may comprise a polymer, metal, etc. and be coupled to a proximal flexible segment that is coupled to the proximal mounting collar 73012 and a distal flexible segment that is coupled to the distal mounting collar 73022. The proximal flexible segment and the distal flexible segment may be fabricated from polymer, rubber, etc. that is more flexible than the center segment. In the embodiment illustrated in FIGS. 71 and 72, the shaft guide 73000 is fabricated from a single flexible material (polymer, rubber, etc.) and additionally includes a proximal flexible ribbed segment 73032 and a distal flexible ribbed segment 73034 formed therein to facilitate additional flexibility.

In the illustrated example, the shaft guide 73000 defines a central shaft guide axis SGA that extends from the shaft guide proximal end 73010 to the shaft guide distal end 73020. The shaft guide 73000 further comprises a first passage 73040 that opens through the proximal mounting collar 73012 on a first side RP₁ of a reference plane RP that extends transversely through the shaft guide axis SGA. In the illustrated arrangement, the first passage 73040 is configured to operably support the portion of the flexible closure drive shaft 72000 that spans between the proximal mounting member 71100 and the distal mounting member 71300. As can be seen in FIG. 71, in at least one arrangement, the first passage 73040 passes through the reference plane RP at least two times and opens through the distal mounting collar 73022 on the first side RP₁ of the reference plane RP.

In the illustrated example, the shaft guide 73000 further comprises a second passage 73050 that opens through the proximal mounting collar 73012 on a second side RP₂ of the reference plane RP. In the illustrated arrangement, the second passage 73050 is configured to operably support the portion of the flexible firing drive shaft 72100 that spans between the proximal mounting member 71100 and the distal mounting member 71300. As can be seen in FIG. 71, in at least one arrangement, the second passage 73050 passes through the reference plane RP at least two times and opens through the distal mounting collar 73022 on the second side RP₂ of the reference plane RP. Such arrangement serves to operably support the flexible closure drive shaft 72000 and the flexible firing drive shaft 72100 regardless of the articulated position of the end effector 200. In addition, such “twisted” arrangement of the first passage 73040 and the second passage 73050 forms a non-preferential bending plane through the shaft guide. In other arrangements, the shaft guide 73000 may be coupled to the proximal mounting member 71100 and the distal mounting member 71300 to facilitate relative rotation therebetween.

Referring now to FIGS. 64 and 74, in at least one arrangement, the surgical instrument comprises an articulation system 74000 that comprises a horizontal articulation drive 74100 and a vertical articulation drive 74200. In one aspect, the horizontal articulation drive 74100 comprises a horizontal articulation cable 74110 that is journaled on a horizontal drive pulley 74120 that may be supported in or by the housing or robotic system. In other arrangements, the horizontal drive pulley 74120 may be supported in a portion of the shaft assembly 100. In at least one embodiment, the horizontal drive pulley 74120 comprises a horizontal drive gear 74122 that is in meshing engagement with a horizontal drive rack 74124. The horizontal drive rack 74124 is configured to be driven axially by a corresponding motor drive unit (not shown) supported in or by the housing or robotic system.

As can be seen in FIG. 64, the horizontal articulation cable 74110 comprises a first horizontal cable end portion 74112 that extends through a corresponding passage in the proximal mounting member 71100 and is attached to the distal mounting member 71300. The horizontal articulation cable 74110 further comprises a second horizontal cable end portion 74114 that extends through a corresponding passage in the proximal mounting member 71100 and is attached to the distal mounting member 71300. Rotation of the horizontal drive pulley 71420 in a first direction will cause the end effector 200 to articulate in a first horizontal direction and rotation of the horizontal drive pulley 71420 in a second direction will cause the end effector 200 to articulate in a second horizontal direction (arrows HD in FIG. 63).

Still referring to FIGS. 64 and 74, the vertical articulation drive 74200 comprises a vertical articulation cable 74210 that is journaled on a vertical drive pulley 74220 that may be supported in or by the housing or robotic system. In other arrangements, the vertical drive pulley 74220 may be supported in a portion of the shaft assembly 100. In at least one embodiment, the vertical drive pulley 74220 comprises a vertical drive gear (not shown) that is in meshing engagement with a vertical drive rack 74224. The vertical drive rack 74224 is configured to be driven axially by a corresponding motor drive unit supported in or by the housing or robotic system.

As can be seen in FIG. 64, the vertical articulation cable 74210 comprises a first vertical cable end portion 74212 that extends through a corresponding passage in the proximal mounting member 71100 and is attached to the distal mounting member 71300. The vertical articulation cable 74210 further comprises a second horizontal cable end portion 74214 that extends through a corresponding passage in the proximal mounting member 71100 and is attached to the distal mounting member 71300. Rotation of the vertical drive pulley 74220 in a first direction will cause the end effector 200 to articulate in a first vertical direction and rotation of the vertical drive pulley 74220 in a second direction will cause the end effector 200 to articulate in a second vertical direction (arrows VD in FIG. 63). When the horizontal articulation drive 74100 and a vertical articulation drive 74200 are operated in concert, they can articulate the end effector in any combination of planes creating a three dimensional cone of articulation. In various arrangements springs may be employed in connection with the cables and or the drive pulleys to reduce/minimize backlash during operation.

FIGS. 75 and 76 illustrate another articulatable surgical end effector 75000 that is configured to articulate in a single plane through an articulation angle AAG that is approximately sixty five degrees or more. Such articulatable end effectors may be particularly useful in performing a lower anterior resection (LAR) of the colon, for example. In one instance, the surgical end effector 75000 comprises a surgical stapling device that is capable of cutting and stapling tissue. Other applications may employ a surgical end effector that is configured to cut and fasten tissue with ultrasound, harmonic, radio frequency energy, etc. In the illustrated example, the surgical end effector 75000 is substantially similar to end effector 200 described above, except for the differences discussed herein.

The illustrated surgical end effector 75000, for example, comprises a first jaw 201 and an anvil jaw 203, the various details of which were provided above. The surgical end effector further comprises a distal joint component 75450 that is similar to the joint component 450 discussed above. In at least one arrangement, the distal joint component 75450 is attached to the first jaw 201 by a retention ring 358 in the various manners described herein. In accordance with one aspect, a distal articulation cam 75500 is coupled to the distal joint component 75450. The distal articulation cam 75500 is configured to cammingly interface with a proximal articulation cam 75600 that operably interfaces with a shaft assembly 75410.

In accordance with at least one aspect, the shaft assembly 75410 is substantially similar to shaft assembly 410 described herein except for the noted differences. In one example, the shaft assembly comprises an outer shaft 75411 that operably interfaces with a proximal shaft joint component 75330. In accordance with one aspect, the proximal articulation cam 75600 is supported by the proximal shaft joint component 75330 for rotation about the shaft axis SA. In one embodiment, for example, the proximal articulation cam 75600 comprises a ring gear 75610 that is configured to meshingly interface with an articulation drive gear 75710 that is attached to an articulation drive shaft 75700 that is rotatably supported in the shaft assembly 75410. The articulation drive shaft 75700 operably interfaces with a source of rotary motion (e.g., a motor, etc.) that is supported in or by the housing or robotic system. Rotation of the articulation drive shaft 75700 in a first rotary direction will cause a proximal cam face 75620 on the proximal articulation cam 75600 to cammingly interface with a distal cam face 75520 on the distal articulation cam 75500 to articulate the surgical end effector 75000 through the articulation angle AAG. Continued rotation of the articulation drive shaft 75700 in the first direction will cause the surgical end effector to articulate through a single articulation plane until the surgical end effector 75000 reaches the maximum articulated position (articulation angle AAG equals approximately 65°) illustrated in FIG. 76, for example. Rotation of the articulation drive shaft 75700 in a second rotary direction will cause the proximal articulation cam 75600 and distal articulation cam 75500 to cammingly drive the surgical end effector 75000 back to the unarticulated position illustrated in FIG. 75.

The embodiment depicted in FIGS. 75 and 76, in accordance with one aspect of the present disclosure, may employ the closure drive system and firing drive system depicted in FIGS. 44-48 that were described in detail above. It will be appreciated that the closure drive system and firing drive system serve to maintain the distal cam face 75520 in camming engagement with the proximal cam face 75620. FIGS. 75 and 76 are “plan” or “top” views which only illustrate the closure drive arrangement with it being understood that the firing drive arrangement is located directly beneath the closure drive arrangement in the manners described herein. For example, as can be seen in FIGS. 75 and 76, the closure drive arrangement comprises a proximal closure drive shaft portion 68002, an intermediate closure drive shaft portion 68100, and a distal closure drive shaft portion 68300 that operably interfaces with closure components described herein to open and close the anvil 203. As was also described above, a proximal closure drive shaft 68010 and a distal closure drive shaft 68300 are attached to a closure coupler member 68110 for movement relative thereto. The proximal closure drive shaft 68010 may operably interface with a source of rotary closure motions (e.g., a motor, etc.) that is operably supported by or in a housing or portion of a robotic system, for example. Rotation of the proximal closure drive shaft 68010 in a first direction may result in the closure of the anvil 203 and rotation of the proximal closure drive shaft 68010 in a second rotary direction, will result in the anvil 203 moving from a closed position to an open position in the manners described herein. The firing drive system that may be employed in connection with this embodiment was described in detail above and will not be repeated here for the sake of brevity.

Other embodiments may employ the shaft embodiments comprising universally movable joints 60200 in the various manners and arrangements disclosed herein. The distal articulation cam 75500 and the proximal articulation cam 75500 define an articulation region 75100 and facilitate single plane, single direction, high-degree of articulation utilizing a rotating cam twist joint.

Many of the surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. In certain instances, the motors disclosed herein may comprise a portion or portions of a robotically controlled system. Moreover, any of the end effectors and/or tool assemblies disclosed herein can be utilized with a robotic surgical instrument system. U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, discloses several examples of a robotic surgical instrument system in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. Various embodiments are envisioned which deploy fasteners other than staples, such as clamps or tacks, for example. Moreover, various embodiments are envisioned which utilize any suitable means for sealing tissue. For instance, an end effector in accordance with various embodiments can comprise electrodes configured to heat and seal the tissue. Also, for instance, an end effector in accordance with certain embodiments can apply vibrational energy to seal the tissue.

EXAMPLES Set No. 1 Example 1

A universally movable drive shaft for a surgical instrument, wherein the universally movable drive shaft comprises a first movable joint that comprises a first joint spine that defines a first axis and a second axis that is transverse to the first axis. The first movable joint further comprises a first U-shaped bridge that is movably and non-removably journaled on the first joint spine for pivotal travel relative thereto about the first axis. The first movable joint further comprises a second U-shaped bridge that is movably and non-removably journaled on the first joint spine for pivotal travel relative thereto about the second axis. The second U-shaped bridge further comprises a third U-shaped bridge of a second movable joint. The second movable joint comprises a second joint spine that defines a third axis and a fourth axis that is transverse to the third axis. The third U-shaped bridge is movably and non-removably journaled on the second joint spine for pivotal travel relative thereto about the fourth axis. The second movable joint further comprises a fourth U-shaped bridge that is movably and non-removably journaled on the second joint spine for pivotal travel relative thereto about the third axis

Example 2

The universally movable drive shaft of Example 1, wherein the fourth U-shaped bridge further comprises a fifth U-shaped bridge of a third movable joint. The third movable joint comprises a third joint spine that defines a fifth axis and a sixth axis that is transverse to the fifth axis. The fifth U-shaped bridge is movably and non-removably journaled on the third joint spine for pivotal travel relative thereto about the sixth axis. The third movable joint further comprises a sixth U-shaped bridge that is movably and non-removably journaled on the third joint spine for pivotal travel relative thereto about the fifth axis.

Example 3

The universally movable drive shaft of Examples 1 or 2, wherein the first U-shaped bridge comprises a first joint cap that is rotatably supported on a first conical portion of the first joint spine for rotatable travel therearound about the first axis and the first joint cap is spaced from the first conical portion by a first joint space. A second joint cap is rotatably supported on a second conical portion of the first joint spine for rotational travel therearound about the first axis, wherein the second joint cap is spaced from the second conical portion by a second joint space. The second U-shaped bridge comprises a first joint ring that is journaled on a portion of the first joint spine for rotation therearound about the second axis, wherein the first joint ring is retained on the first joint spine by a first flared end of the first joint spine, and wherein the first joint ring is spaced from the portion of the first joint spine by a third joint space. A second joint ring is journaled on another portion of the first joint spine for rotation therearound about the second axis, wherein the second joint ring is spaced from the another portion of the first joint spine by a fourth joint space.

Example 4

The universally movable drive shaft of Examples 1, 2 or 3, wherein the universally movable drive shaft is fabricated from a build material that is converted from a first state to a second state by a manufacturing process.

Example 5

The universally movable drive shaft of Example 4, wherein the manufacturing process comprises a three dimensional printing process.

Example 6

The universally movable drive shaft of Example 4 or 5, wherein the first joint space is configured to contain a first amount of the build material in the first state during formation of the first universally movable drive shaft and exit therefrom after the formation. The second joint space is configured to contain a second amount of the build material in the first state therein during the formation and exit therefrom after the formation. The third joint space is configured to contain a third amount of the build material in the first state during the formation and exit therefrom after the formation. The fourth joint space is configured to contain a fourth amount of the build material in the first state during the formation and exit therefrom after the formation.

Example 7

A universally movable joint for a shaft of a surgical instrument. The universally movable joint comprises a joint spine that defines a first axis and a second axis that is transverse to the first axis. The joint spine comprises a first axle segment and a second axle segment that are each aligned on the first axis. The first axle segment comprises a flared first end and the second axle segment comprises a flared second end. The joint spine further comprises a third axle segment and a fourth axle segment that are each aligned on the second axis. The universally movable joint further comprises a first U-joint that is pivotally journaled on the joint spine for pivotal travel relative thereto about the first axis. The first U-joint comprises a first joint ring journaled on the first axle segment for rotation therearound and is retained thereon by the flared first end. The first U-joint further comprises a second joint ring that is journaled on the second axle segment for rotation therearound and is retained thereon by the flared second end. The first U-joint further comprises a first bridge that extends between the first joint ring and the second joint ring. The universally movable joint further comprises a second U-joint that is pivotally journaled on the joint spine for pivotal travel relative thereto about the second axis. The second U-joint comprises a third joint cap that is rotatably journaled on the third axle segment for rotation therearound about the second axis. The second U-joint further comprises a fourth joint cap that is rotatably journaled on the fourth axle segment for rotation therearound about the second axis. The second U-joint further comprises a second bridge that extends between the third joint cap and the fourth joint cap to retain the third joint cap on the third axle segment and the fourth joint cap on the fourth axle segment.

Example 8

The universally movable joint of Example 7, wherein the third axle segment terminates in a third conical end, and wherein the fourth axle segment terminates in a fourth conical end.

Example 9

The universally movable joint of Example 8, wherein the first joint ring comprises a first joint ring inner surface, wherein the first joint ring inner surface is spaced from the first axle segment and the flared first end to define a first joint space. The second joint ring comprises a second joint ring inner surface, wherein the second joint ring inner surface is spaced from the second axle segment and the flared second end to define a second joint space. The third joint cap comprises a third axle surface that is spaced from the third axle segment a third axle joint space. A third conical surface is spaced from the third conical end a third tapered joint space that communicates with the third axle joint space to form a third joint space. A third exit hole extends through the third joint cap and communicates with the third joint space. The fourth joint cap comprises a fourth axle surface that is spaced from the fourth axle segment a fourth axle joint space. A fourth conical surface is spaced from the fourth conical end a fourth tapered joint space that communicates with the fourth axle joint space to form a fourth joint space. A fourth exit hole extends through the fourth joint cap and communicates with the fourth joint space.

Example 10

The universally movable joint of Examples 7 or 8, wherein the universally movable joint further comprises a first joint space between the first ring and the first axle. A second joint space is between the second ring and the second axle. A third joint space is between the third joint cap and the third axle segment and a fourth joint space is between the fourth joint cap and the fourth axle segment.

Example 11

The universally movable joint of Examples 7, 8, 9 or 10, wherein the universally movable joint is fabricated from a build material that is converted from a first state to a second state by a manufacturing process.

Example 12

The universally movable joint of Example 11, wherein the manufacturing process comprises a three dimensional printing process.

Example 13

The universally movable joint of Examples 11 or 12, wherein the first joint space is configured to contain a first amount of the build material in the first state therein during formation of the multi-planar movable joint. The second joint space is configured to contain a second amount of the build material in the first state therein during the formation. The third joint space is configured to contain a third amount of the build material in the first state during the formation and the fourth joint space is configured to contain a fourth amount of the build material in the first state during the formation.

Example 14

The universally movable joint of Example 13, wherein the first joint space is configured to enable at least some of the first amount of the build material in the first state to exit therefrom after the formation of the universally movable joint. The second joint space is configured to enable at least some of the second amount of the build material in the first state to exit therefrom after the formation. The third joint cap comprises a third exit hole sized to permit at least some of the third amount of the build material in the first state to exit therethrough after the formation. The fourth joint cap comprises a fourth exit hole sized to permit at least some of the fourth amount of the build material in the first state to exit therethrough after the formation.

Example 15

The universally movable joint of Example 14, wherein the first joint ring comprises a first joint ring outer surface. The third joint cap comprises a third joint cap outer surface and the fourth joint cap comprises a fourth joint cap outer surface. The first joint ring outer surface is spaced from the third joint cap outer surface a first fillet space. The first joint ring outer surface is spaced from the fourth joint cap surface a second fillet space. The second joint ring comprises a second joint ring outer surface that is spaced from the third cap outer surface a third fillet space. The second joint ring outer surface is spaced from the fourth cap outer surface a fourth fillet space.

Example 16

The universally movable joint of Example 15, wherein the first fillet space is configured to permit at least some other of the third amount of the build material in the first state to exit therethrough after the formation. The second fillet space is configured to permit at least some other of the fourth amount of the build material in the first state to exit therethrough after the formation. The third fillet space and the fourth fillet space are each configured to permit at least some other of the second amount of the build material in the first state to exit therethrough.

Example 17

The universally movable joint of Examples 7, 8, 9, 10, 11, 12, 13, 14, 15 or 16, wherein the universally movable joint further comprises a mounting member that protrudes from one of the first bridge and the second bridge.

Example 18

The universally movable joint of Examples 11, 12, 13, 14, 15, 16 or 17, wherein a support material that differs from the build material is contained within the first joint space, the second joint space, the third joint space, and the fourth joint space during the formation.

Example 19

The universally movable joint of Examples 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 or 18, wherein the joint spine is formed from a first build material, and wherein the first U-joint and the second U-joint are each formed from a second build material that differs from the first build material.

Example 20

An articulation joint assembly for facilitating multi-axis articulation of a surgical end effector relative to a shaft assembly of a surgical instrument, wherein the shaft assembly defines a shaft axis, and wherein the articulation joint assembly comprises a proximal mounting member that is configured to interface with the shaft assembly. The articulation joint assembly further comprises a distal mounting member that is configured to interface with the surgical end effector. The articulation joint assembly additionally comprises a plurality of articulation link assemblies that are attached to the proximal mounting member and the distal mounting member and extend therebetween. Each articulation link assembly comprises a pair of universally movable joints. Each universally movable joint comprises a joint spine that defines a first axis and a second axis that is transverse to the first axis. The first axis and the second axis are transverse to the shaft axis. A first bridge is movably and non-removably journaled on the joint spine for pivotal travel relative thereto about the first axis. A second bridge is movably and non-removably journaled on the joint spine for pivotal travel relative thereto about the second axis. An attachment member protrudes from the second bridge and is configured to movably affix the universally movable joint to a corresponding one of the proximal mounting member and the distal mounting member. The articulation link assembly further comprises an elongate link that protrudes from the first bridge on one of the universally movable joints of the pair of universally movable joints and the first bridge on the other one of the universally movable joints of the pair of universally movable joints and extends therebetween.

Example 21

The articulation joint assembly of Example 20, wherein the elongate link defines a link axis that curves around the shaft axis and is not parallel thereto.

Example 22

The articulation joint assembly of Examples 20 or 21, wherein the attachment member of one of the universally movable joints is configured to movably affix one of the universally movable joints to the proximal mounting member such that the universally movable joint is axially movable relative thereto. The attachment member of the other one of the universally movable joints is configured to movably affix the other one of the universally movable joints to the distal mounting member such that the other one of the universally movable joints is axially movable relative thereto.

Example 23

The articulation joint assembly of Examples 20, 21 or 22, wherein each attachment member defines an attachment member axis that is parallel to the shaft axis.

Example 24

The articulation joint assembly of Examples 20, 21, 22 or 23, wherein the second bridge comprises a first joint cap that is rotatably supported on a first conical portion of the joint spine for rotatable travel therearound about the first axis and is spaced from the first conical portion by a first joint space. The second bridge further comprises a second joint cap that is rotatably supported on a second conical portion of the joint spine for rotational travel therearound about the first axis and is spaced from the second conical portion by a second joint space. The first bridge comprises a first joint ring that is journaled on a first axle portion of the joint spine for rotation therearound about the second axis and is spaced from the first axle portion of the joint spine by a third joint space. The first bridge further comprises a second joint ring that is journaled on a second axle portion of the joint spine for rotation therearound about the second axis and is spaced from the second axle portion of the joint spine by a fourth joint space.

Example 25

The articulation joint assembly of Examples 20, 21, 22, 23 or 24, wherein each articulation link assembly is fabricated from a build material that is converted from a first state to a second state by a manufacturing process.

Example 26

The articulation joint assembly of Example 25, wherein the manufacturing process comprises a three dimensional printing process.

Example 27

The articulation joint assembly of Examples 25 or 26, wherein the first joint space is configured to contain a first amount of the build material in the first state therein during formation of the articulation link assembly and exit therefrom after the formation, wherein the second joint space is configured to contain a second amount of the build material in the first state therein during the formation and exit therefrom after the formation, wherein the third joint space is configured to contain a third amount of the build material in the first state therein during the formation and exit therefrom after the formation, and wherein the fourth joint space is configured to contain a fourth amount of the build material in the first state therein during the formation and exit therefrom after the formation.

Example 28

A method comprising providing a build material that is convertible from a first powdered state to a second solid state. The method further comprises converting a first amount of the build material from the first powdered state to the second solid state to form a first cross-shaped joint spine, wherein the first cross-shaped joint spine defines a first vertical axis and a first horizontal axis that is transverse to the first vertical axis. The method further comprises converting a second amount of the build material from the first powdered state to the second solid state to form a first vertical joint member configured to non-removably pivot on the first cross-shaped joint spine about the first vertical axis. The method additionally comprises converting a third amount of the build material from the first powdered state to the second solid state to form a first horizontal joint member configured to non-removably pivot on the first cross-shaped joint spine about the first horizontal axis. The method also comprises evacuating all amounts of the build material remaining in the first powdered state from between the first cross-shaped joint spine, the vertical joint member, and the horizontal joint member.

Example 29

The method of Example 28, wherein converting a first amount of the build material from the first powdered state to the second solid state method further comprises forming a second cross-shaped joint spine, wherein the second cross-shaped joint spine defines a second vertical axis and a second horizontal axis that is transverse to the second vertical axis. Converting a second amount of the build material from the first powdered state to the second solid state to form a first vertical joint member further comprises forming a second vertical joint member that is configured to non-removably pivot on the second cross-shaped joint spine about the second vertical axis. Converting a third amount of the build material from the first powdered state to the second solid state to form a first horizontal joint member further comprises forming a second horizontal joint member that protrudes from the first vertical joint member and is configured to non-removably pivot on the second cross-shaped joint spine about the second horizontal axis.

Example 30

The method of Example 29, wherein converting a first amount of the build material from the first powdered state to the second solid state further comprises forming a third cross-shaped joint spine that defines a third vertical axis and a third horizontal axis that is transverse to the third vertical axis. Converting a second amount of the build material from the first powdered state to the second solid state to form a first vertical joint member further comprises forming a third vertical joint member that is configured to non-removably pivot on the third cross-shaped joint spine about the third vertical axis. Converting a third amount of the build material from the first powdered state to the second solid state to form a first horizontal joint member further comprises forming a third horizontal joint member that protrudes from the second vertical joint member and is configured to non-removably pivot on the third cross-shaped joint spine about the third horizontal axis.

EXAMPLES Set No. 2 Example 1

A shaft guide for a surgical instrument that includes a shaft assembly that defines a shaft axis and a surgical end effector that is operably coupled to the shaft assembly by an articulation joint. The articulation joint facilitates articulation of the surgical end effector about a first articulation axis that is transverse to the shaft axis and a second articulation axis that is transverse to the shaft axis and the first articulation axis. The shaft guide comprises a shaft guide body that is sized to span across the articulation joint and the first articulation axis and the second articulation axis. The shaft guide body comprises a shaft guide proximal end and a shaft guide distal end. A first passage extends through the shaft guide body and comprises first passage proximal opening in the shaft guide proximal end and a first passage distal opening in the shaft guide distal end. A second passage extends through the shaft guide body and comprises a second passage proximal opening in the shaft guide proximal end and a second passage distal opening in the shaft guide distal end. The second passage proximal opening is oriented in a first orientation relative to the first passage proximal opening and the second passage distal opening is oriented in a second orientation relative to the first passage distal opening in a second orientation that differs from the first orientation.

Example 2

The shaft guide of Example 1, wherein the second passage proximal opening is horizontally aligned with the first passage proximal opening, and wherein the second passage distal opening is vertically aligned with the first passage distal opening.

Example 3

The shaft guide of Examples 1 or 2, wherein a first proximal center of the first passage proximal opening and a second proximal center of the second passage proximal opening lie on a first reference plane. A first distal center of the first passage distal opening and a second distal center of the second passage distal opening lie on a second reference plane that is transverse to the first reference plane.

Example 4

The shaft guide of Examples 1 or 3, wherein the second passage proximal opening is vertically aligned with the first passage proximal opening and the second passage distal opening is horizontally aligned with the first passage distal opening.

Example 5

The shaft guide of Examples 1 or 2, wherein the first passage proximal opening is located on a first side of a first reference plane and the first passage distal opening is located on a first side of a second reference plane that is transverse to the first reference plane. The second passage proximal opening is located on a second side of the first reference plane and the second passage distal opening is located on a second side of the second reference plane.

Example 6

The shaft guide of Examples 3, 4 or 5, wherein a first central portion of said first passage passes through at least one of the first reference plane and the second reference plane and wherein a second central portion of said second passage passes through at least one of the first reference plane and the second reference plane.

Example 7

The shaft guide of Examples 1, 2, 3, 4, 5 or 6, wherein the shaft guide is fabricated from a ductile material that is configured to facilitate twisting flexure of the shaft guide when the surgical end effector is articulated about at least one of the first articulation axis and the second articulation axis.

Example 8

The shaft guide of Examples 1, 2, 3, 4, 5, 6 or 7, wherein the shaft guide proximal end comprises a proximal oval shape and the shaft guide distal end comprises a distal oval shape.

Example 9

The shaft guide of Examples 1, 2, 3, 4, 5, 6, 7 or 8, wherein the shaft guide body comprises a central body portion extending between the shaft guide proximal end and the shaft guide distal end and comprises a centrally disposed bulbous segment.

Example 10

The shaft guide of Example 9, wherein the central body portion further comprises a proximal body portion located between the centrally disposed bulbous segment and the shaft guide proximal end. The proximal body portion comprises a proximal diameter that is less than a diameter of the centrally disposed bulbous segment and corresponds to the first articulation axis. The central body portion further comprises a distal body portion located between the centrally disposed bulbous segment and the shaft guide distal end. The distal body portion comprises a distal diameter that is less than the diameter of the centrally disposed bulbous segment and corresponds to the second articulation axis.

Example 11

The shaft guide of Example 10, wherein the proximal body portion further comprises a first pair of opposed proximal scalloped areas that are proximal to the centrally disposed bulbous segment and a second pair of opposed distal scalloped areas that are distal to the centrally disposed bulbous segment.

Example 12

A shaft guide for a surgical instrument that includes a shaft assembly that defines a shaft axis and a surgical end effector that is operably coupled to the shaft assembly by an articulation joint that facilitates articulation of the surgical end effector through a plurality of articulation planes relative to the shaft axis. The shaft guide comprises a shaft guide body that is sized to span across the articulation joint and comprises a shaft guide proximal end and a shaft guide distal end. The shaft guide further comprises a first passage that extends through the shaft guide body from the shaft guide proximal end to the shaft guide distal end and is configured to operably support a portion of a first drive shaft therethrough. The first passage opens through the shaft guide proximal end on a first side of a reference plane that extends through the shaft axis and opens through the shaft guide distal end on the first side of the reference plane. A first central portion of the first passage passes through the reference plane at at least two locations. The shaft guide further comprises a second passage that extends through the shaft guide body from the shaft guide proximal end to the shaft guide distal end and is configured to operably support a portion of a second drive shaft therethrough. The second passage opens through the shaft guide proximal end on a second side of the reference plane and opens through the shaft guide distal end on the second side of the reference plane. A second central portion of the second passage passes through the reference plane at at least two other locations.

Example 13

The shaft guide of Example 12, wherein the shaft guide is fabricated from a ductile material configured to facilitate twisting flexure of the shaft guide when the surgical end effector is articulated relative to the shaft assembly.

Example 14

The shaft guide of Examples 12 or 13, wherein the shaft guide proximal end is coupled to the shaft assembly and is configured to rotate relative thereto, and wherein the shaft guide distal end is coupled to the surgical end effector and is configured to rotate relative thereto.

Example 15

A surgical instrument comprising a shaft assembly that defines a shaft axis. A surgical end effector is operably coupled to the shaft assembly by an articulation joint that defines a first articulation axis about which the surgical end effector is articulatable relative to the shaft assembly. The first articulation axis is transverse to the shaft axis. The articulation joint further defines a second articulation axis about which the surgical end effector is articulatable relative to the shaft assembly. The second articulation axis is transverse to the shaft axis and the first articulation axis. The articulation joint comprises a shaft guide that comprises a shaft guide proximal end that is adjacent to the shaft assembly and a shaft guide distal end that is adjacent to the surgical end effector. The shaft guide further comprises a shaft guide body that spans the articulation joint and the first articulation axis and the second articulation axis. The shaft guide body defines a shaft guide axis and comprises a first passage that extends through the shaft guide body from the shaft guide proximal end to the shaft guide distal end and is configured to operably support a portion of a first drive shaft. The first passage opens through the shaft guide proximal end on a first side of a first reference plane that extends through the shaft guide axis and opens through the shaft guide distal end on a first side of a second reference plane that extends through the shaft guide axis and is transverse to the first reference plane. A first central portion of the first passage passes through at least one of the first reference plane and the second reference plane. The shaft guide body further comprises a second passage that extends through the shaft guide body from the shaft guide proximal end to the shaft guide distal end and is configured to operably support a portion of a second drive shaft therethrough. The second passage opens through the shaft guide proximal end on a second side of the first reference plane and opens through the shaft guide distal end on a second side of the second reference plane. A second central portion of the second passage passes through at least one of the first reference plane and the second reference plane.

Example 16

The surgical instrument of Example 15, wherein the shaft guide is fabricated from a ductile material configured to facilitate flexure of the shaft guide when the surgical end effector is articulated about at least one of the first articulation axis and the second articulation axis.

Example 17

The surgical instrument of Examples 15 or 16, wherein the first passage comprises a first passage proximal end that opens through the shaft guide proximal end and a first passage distal end that opens through the shaft guide distal end. The second passage comprises a second passage proximal end that opens through the shaft guide proximal end and a second passage distal end that opens through the shaft guide distal end. The first passage proximal end is bisected by the second reference plane and the first passage distal end is bisected by the first reference plane. The second passage proximal end is bisected by the second reference plane and the second passage distal end is bisected by the first reference plane.

Example 18

The surgical instrument of Examples 15, 16 or 17, wherein the shaft guide proximal end comprises a proximal oval shape and wherein the shaft guide distal end comprises a distal oval shape.

Example 19

The surgical instrument of Example 18, wherein the proximal oval shape comprises a proximal long axis that is aligned on the first reference plane, and wherein the distal oval shape comprises a distal long axis that is aligned on the second reference plane.

Example 20

The surgical instrument of Example 19, wherein the first passage comprises a first passage proximal end that opens through the shaft guide proximal end and a first passage distal end that opens through the shaft guide distal end. The second passage comprises a second passage proximal end that opens through the shaft guide proximal end and a second passage distal end that opens through the shaft guide distal end. The first passage proximal end and the second passage proximal end are laterally spaced from each other on the proximal long axis. The first passage distal end and the second passage distal end are vertically spaced from each other on the distal long axis.

EXAMPLES Set No. 3 Example 1

A surgical instrument comprising a shaft assembly that defines a shaft axis. The surgical instrument further comprises a surgical end effector and an articulation joint. The articulation joint comprises a proximal mounting member that is attached to the shaft assembly and a distal mounting member that is attached to the surgical end effector. The articulation joint further comprises a linkage assembly that comprises a first link member that comprises a first link proximal end, a first link distal end, and a first link body that extends between the first link proximal end and the first link distal end. The first link proximal end is coupled to the proximal mounting member to enable the first link proximal end to pivot relative thereto and the first link body to rotate about the shaft axis during articulation of the surgical end effector. The first link distal end is coupled to the distal mounting member to enable the first link distal end to pivot relative thereto and the first link body to rotate about the shaft axis. The linkage assembly further comprises a second link member that comprises a second link proximal end, a second link distal end, and a second link body that extends between the second link proximal end and the second link distal end. The second link proximal end is coupled to the proximal mounting member to enable the second link proximal end to pivot relative thereto and the second link body to rotate about the shaft axis. The second link distal end is coupled to the distal mounting member to enable the second link distal end to pivot relative thereto and the second link body to rotate about the shaft axis.

Example 2

The surgical instrument of Example 1, wherein the linkage assembly further comprises a third link member that comprises a third link proximal end, a third link distal end, and a third link body. The third link proximal end is coupled to the proximal mounting member to enable the third link proximal end to pivot relative thereto and the third link body to rotate about the shaft axis. The third link distal end is coupled to the distal mounting member to enable the third link distal end to pivot relative thereto and the third link body to rotate about the shaft axis.

Example 3

The surgical instrument of Examples 1 or 2, further comprising a flexible shaft guide that spans between the proximal mounting member and the distal mounting member to operably support at least a portion of at least one drive shaft therethrough.

Example 4

The surgical instrument of Examples 1, 2 or 3, wherein the linkage assembly is configured to maintain an axial distance between the proximal mounting member and the distal mounting member during articulation of the surgical end effector relative to the shaft assembly.

Example 5

The surgical instrument of Examples 1, 2, 3 or 4, wherein the first link proximal end is attached to the proximal mounting member at a first proximal attachment location by a first proximal joint assembly that is configured to facilitate pivotal travel of the first link proximal end relative to the proximal mounting member about a two first proximal joint axes that are transverse to each other. The first link distal end is attached to the distal mounting member at a first distal attachment location on the distal mounting member by a first distal joint assembly that is configured to facilitate pivotal travel of the first link distal end relative to the distal mounting member about two first distal joint axes that are transverse to each other. The second link proximal end is attached to the proximal mounting member at a second proximal attachment location by a second proximal joint assembly that is configured to facilitate pivotal travel of the second link proximal end relative to the proximal mounting member about two second proximal joint axes that are transverse to each other. The second link distal end is attached to the distal mounting member at a second distal attachment location on the distal mounting member by a second distal joint assembly that is configured to facilitate pivotal travel of the second link distal end relative to the distal mounting member about two second distal joint axes that are transverse to each other.

Example 6

The surgical instrument of Examples 2, 3 or 5, wherein the third link proximal end is attached to the proximal mounting member at a third proximal attachment location by a third proximal joint assembly that is configured to facilitate pivotal travel of the third link proximal end relative to the proximal mounting member about two third proximal joint axes that are transverse to each other. The third link distal end is attached to the distal mounting member at a third distal attachment location on the distal mounting member by a third distal joint assembly that is configured to facilitate pivotal travel of the third link distal end relative to the distal mounting member about two third distal joint axes that are transverse to each other.

Example 7

The surgical instrument of Examples 6, wherein first link proximal end is attached to the proximal mounting member at a first proximal attachment location by a first proximal joint assembly that is configured to facilitate pivotal travel of the first link proximal end relative to the proximal mounting member about a two first proximal joint axes that are transverse to each other. The first link distal end is attached to the distal mounting member at a first distal attachment location on the distal mounting member by a first distal joint assembly that is configured to facilitate pivotal travel of the first link distal end relative to the distal mounting member about two first distal joint axes that are transverse to each other. The second link proximal end is attached to the proximal mounting member at a second proximal attachment location by a second proximal joint assembly that is configured to facilitate pivotal travel of the second link proximal end relative to the proximal mounting member about two second proximal joint axes that are transverse to each other. The second link distal end is attached to the distal mounting member at a second distal attachment location on the distal mounting member by a second distal joint assembly that is configured to facilitate pivotal travel of the second link distal end relative to the distal mounting member about two second distal joint axes that are transverse to each other.

Example 8

The surgical instrument of Examples 2, 3, 6 or 7, wherein when the distal mounting member is axially aligned with the proximal mounting member on the shaft axis, the first distal attachment location on the distal mounting member is diametrically opposite to the first proximal attachment location on the proximal mounting member, the second distal attachment location on the distal mounting member is diametrically opposite to the second proximal attachment location on the proximal mounting member, and the third distal attachment location on the distal mounting member is diametrically opposite to the third proximal attachment location on the proximal mounting member.

Example 9

The surgical instrument of Example 3, wherein the first link body comprises at least one first link curved surface that is configured to accommodate passage of the flexible shaft guide between the proximal mounting member and the distal mounting member. The second link body comprises at least one second link curved surface that is configured to accommodate passage of the flexible shaft guide between the proximal mounting member and the distal mounting member. The third link body comprises at least one third link curved surface that is configured to accommodate passage of the flexible shaft guide between the proximal mounting member and the distal mounting member.

Example 10

The surgical instrument of Examples 3 or 9, wherein the flexible shaft guide is rotatably movable relative to at least one of the proximal mounting member and the distal mounting member.

Example 11

The surgical instrument of Examples 3, 9 or 10, wherein the flexible shaft guide comprises a shaft guide body that is sized to extend between the proximal mounting member and the distal mounting member. The shaft guide body comprises a shaft guide proximal end portion that is configured to be retained in a proximal shaft hole in the proximal mounting member and rotate therein. The shaft guide body further comprises a proximal flexible ribbed segment located adjacent to the shaft guide proximal end portion. The shaft guide body additionally comprises a shaft guide distal end portion that is configured to be retained in a distal shaft hole in the distal mounting member and rotate therein. A distal flexible ribbed segment is located adjacent to the shaft guide distal end portion.

Example 12

The surgical instrument of Example 11, wherein the flexible shaft guide further comprises a first passage that extends through the shaft guide body from the shaft guide proximal end to the shaft guide distal end and is configured to operably support a portion of a first drive shaft therethrough. The first passage opens through the shaft guide proximal end on a first side of a reference plane that extends through the shaft axis. The first passage opens through the shaft guide distal end on the first side of the reference plane and a first central portion of the first passage passes through the reference plane at at least two first locations. The flexible shaft guide further comprises a second passage that extends through the shaft guide body from the shaft guide proximal end to the shaft guide distal end and is configured to operably support a portion of a second drive shaft therethrough. The second passage opens through the shaft guide proximal end on a second side of the reference plane. The second passage opens through the shaft guide distal end on the second side of the reference plane and a second central portion of the second passage passes through the reference plane at at least two second locations.

Example 13

The surgical instrument of Example 7, wherein the first proximal joint assembly comprises a first proximal attachment link that is pivotally coupled to the first link proximal end to facilitate pivotal travel of the first link proximal end relative to the first proximal attachment link about one of the first proximal joint axes. The first proximal attachment link is pivotally coupled to the proximal mounting member for pivotal travel relative thereto about the other one of the first proximal joint axes. The second proximal joint assembly comprises a second proximal attachment link that is pivotally coupled to the second link proximal end to facilitate pivotal travel of the second link proximal end relative to the second proximal attachment link about one of the second proximal joint axes. The second proximal attachment link is pivotally coupled to the proximal mounting member for pivotal travel relative thereto about the other one of the second proximal joint axes. The third proximal joint assembly comprises a third proximal attachment link that is pivotally coupled to the third link proximal end to facilitate pivotal travel of the third link proximal end relative to the third proximal attachment link about one of the third proximal joint axis. The third proximal attachment link is pivotally coupled to the proximal mounting member for pivotal travel relative thereto about the other one of the third proximal joint axes.

Example 14

The surgical instrument of Examples 7 or 13, wherein the first distal joint assembly comprises a first distal attachment link pivotally that is coupled to the first link distal end to facilitate pivotal travel of the first link distal end relative to the first distal attachment link about one of the first distal joint axes. The first distal attachment link is pivotally coupled to the distal mounting member for pivotal travel relative thereto about the other one of the first distal joint axes. The second distal joint assembly comprises a second distal attachment link that is pivotally coupled to the second link distal end to facilitate pivotal travel of the second link distal end relative to the second distal attachment link about one of the second distal joint axes. The second distal attachment link is pivotally coupled to the distal mounting member for pivotal travel relative thereto about the other one of the second distal joint axes. The third distal joint assembly comprises a third distal attachment link that is pivotally coupled to the third link distal end to facilitate pivotal travel of the third link distal end relative to the third distal attachment link about one of the third distal joint axis. The third distal attachment link is pivotally coupled to the distal mounting member for pivotal travel relative thereto about the other one of the third distal joint axes.

Example 15

The surgical instrument of Examples 7, 13 or 14, wherein the first link member, the first proximal joint assembly, and the first distal joint assembly are formed as a single first link assembly by a three dimensional printing process. The second link member, the second proximal joint assembly, and the second distal joint assembly are formed as a single second link assembly by the three dimensional printing process. The third link member, the third proximal joint assembly, and the third distal joint assembly are formed as a single third link assembly by the three dimensional printing process.

Example 16

The surgical instrument of Examples 7, 13, 14 or 15, wherein the first proximal joint assembly interfaces with the proximal mounting member to facilitate axial movement of the first proximal joint assembly relative to the proximal mounting member. The second proximal joint assembly interfaces with the proximal mounting member to facilitate axial movement of the second proximal joint assembly relative to the proximal mounting member. The third proximal joint assembly interfaces with the proximal mounting member to facilitate axial movement of the third proximal joint assembly relative to the proximal mounting member.

Example 17

The surgical instrument of Examples 7, 13, 14, 15 or 16 wherein the first distal joint assembly interfaces with the distal mounting member to facilitate axial movement of the first distal joint assembly relative to the distal mounting member. The second distal joint assembly interfaces with the distal mounting member to facilitate axial movement of the second distal joint assembly relative to the distal mounting member. The third distal joint assembly interfaces with the distal mounting member to facilitate axial movement of the third distal joint assembly relative to the distal mounting member.

Example 18

The surgical instrument of Examples 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 or 17, wherein the first link member comprises a first circular cross-sectional shape. The second link member comprises a second circular cross-sectional shape. The third link member comprises a third circular cross-sectional shape.

Example 19

The surgical instrument of Examples 2, 3, 4, 5, 6, 7,8, 9, 10, 11, 12, 13, 14 15, 16, 17 or 18, wherein the first link body is partially twisted about the shaft axis. The second link body is partially twisted about the shaft axis. The third link body is partially twisted about the shaft axis.

Example 20

An articulation joint assembly for facilitating multi-axis articulation of a surgical end effector relative to a shaft assembly of a surgical instrument. The articulation joint assembly comprises a proximal mounting member that is configured to interface with the shaft assembly and a distal mounting member that is configured to interface with the surgical end effector. The articulation joint assembly further comprises a linkage assembly that comprises a first link member that comprise a first link proximal end that operably interfaces with the proximal mounting member such that the first link proximal end is axially movable relative to the proximal mounting member and is pivotable about two first proximal joint axes that are transverse to each other. The first link member further comprises a first link distal end that operably interfaces with the distal mounting member such that the first link distal end is axially movable relative to the distal mounting member and is pivotable about two first distal joint axes that are transverse to each other. The linkage assembly further comprises a second link member that comprises a second link proximal end that operably interfaces with the proximal mounting member such that the second link proximal end is axially movable relative to the proximal mounting member and is pivotable about two second proximal joint axes that are transverse to each other. The second link member further comprises a second link distal end that operably interfaces with the distal mounting member such that the second link distal end is axially movable relative to the distal mounting member and is pivotable about two second distal joint axes that are transverse to each other. The linkage assembly also comprises a third link member that comprises a third link proximal end that operably interfaces with the proximal mounting member such that the third link proximal end is axially movable relative to the proximal mounting member and is pivotable about two third proximal joint axes that are transverse to each other. The third link member further comprises a third link distal end that operably interfaces with the distal mounting member such that the third link distal end is axially movable relative to the distal mounting member and is pivotable about two third distal joint axes that are transverse to each other.

Example 21

The articulation joint assembly of Example 20, further comprising a flexible shaft guide that spans between the proximal mounting member and the distal mounting member to flexibly support two drive shafts extending therebetween.

Many of the surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. In certain instances, the motors disclosed herein may comprise a portion or portions of a robotically controlled system. Moreover, any of the end effectors and/or tool assemblies disclosed herein can be utilized with a robotic surgical instrument system. U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, discloses several examples of a robotic surgical instrument system in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. Various embodiments are envisioned which deploy fasteners other than staples, such as clamps or tacks, for example. Moreover, various embodiments are envisioned which utilize any suitable means for sealing tissue. For instance, an end effector in accordance with various embodiments can comprise electrodes configured to heat and seal the tissue. Also, for instance, an end effector in accordance with certain embodiments can apply vibrational energy to seal the tissue.

The entire disclosures of:

-   U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE,     which issued on Apr. 4, 1995; -   U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT     HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on     Feb. 21, 2006; -   U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING AND     FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued on     Sep. 9, 2008; -   U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL     INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS, which     issued on Dec. 16, 2008; -   U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING AN     ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010; -   U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS,     which issued on Jul. 13, 2010; -   U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLE     FASTENER CARTRIDGE, which issued on Mar. 12, 2013; -   U.S. patent application Ser. No. 11/343,803, entitled SURGICAL     INSTRUMENT HAVING RECORDING CAPABILITIES, now U.S. Pat. No.     7,845,537; -   U.S. patent application Ser. No. 12/031,573, entitled SURGICAL     CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb.     14, 2008; -   U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS     FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008,     now U.S. Pat. No. 7,980,443; -   U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVEN     SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411; -   U.S. patent application Ser. No. 12/249,117, entitled POWERED     SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE     FIRING SYSTEM, now U.S. Pat. No. 8,608,045; -   U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVEN     SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL     CONTROL ASSEMBLY, filed Dec. 24, 2009, now U.S. Pat. No. 8,220,688; -   U.S. patent application Ser. No. 12/893,461, entitled STAPLE     CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613; -   U.S. patent application Ser. No. 13/036,647, entitled SURGICAL     STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No.     8,561,870; -   U.S. patent application Ser. No. 13/118,241, entitled SURGICAL     STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS,     now U.S. Pat. No. 9,072,535; -   U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLE     SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15,     2012, now U.S. Pat. No. 9,101,358; -   U.S. patent application Ser. No. 13/800,025, entitled STAPLE     CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013,     now U.S. Pat. No. 9,345,481; -   U.S. patent application Ser. No. 13/800,067, entitled STAPLE     CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013,     now U.S. Patent Application Publication No. 2014/0263552; -   U.S. Patent Application Publication No. 2007/0175955, entitled     SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER     LOCKING MECHANISM, filed Jan. 31, 2006; and -   U.S. Patent Application Publication No. 2010/0264194, entitled     SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR,     filed Apr. 22, 2010, now U.S. Pat. No. 8,308,040, are hereby     incorporated by reference herein.

Although various devices have been described herein in connection with certain embodiments, modifications and variations to those embodiments may be implemented. Particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined in whole or in part, with the features, structures or characteristics of one or more other embodiments without limitation. Also, where materials are disclosed for certain components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to perform a given function or functions. The foregoing description and following claims are intended to cover all such modification and variations.

The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, a device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps including, but not limited to, the disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. In particular, a reconditioning facility and/or surgical team can disassemble a device and, after cleaning and/or replacing particular parts of the device, the device can be reassembled for subsequent use. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

The devices disclosed herein may be processed before surgery. First, a new or used instrument may be obtained and, when necessary, cleaned. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and instrument may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, and/or high-energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in the sterile container. The sealed container may keep the instrument sterile until it is opened in a medical facility. A device may also be sterilized using any other technique known in the art, including but not limited to beta radiation, gamma radiation, ethylene oxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials do not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. 

What is claimed is:
 1. A universally movable drive shaft for a surgical instrument, wherein said universally movable drive shaft comprises: a first movable joint comprising: a first joint spine defining a first axis and a second axis that is transverse to said first axis; a first U-shaped bridge movably and non-removably journaled on said first joint spine for pivotal travel relative thereto about said first axis; and a second U-shaped bridge movably and non-removably journaled on said first joint spine for pivotal travel relative thereto about said second axis, wherein said second U-shaped bridge further comprises a third U-shaped bridge of a second movable joint, wherein said second movable joint comprises: a second joint spine defining a third axis and a fourth axis that is transverse to said third axis, wherein said third U-shaped bridge is movably and non-removably journaled on said second joint spine for pivotal travel relative thereto about said fourth axis; and a fourth U-shaped bridge movably and non-removably journaled on said second joint spine for pivotal travel relative thereto about said third axis.
 2. The universally movable drive shaft of claim 1, wherein said fourth U-shaped bridge further comprises a fifth U-shaped bridge of a third movable joint, wherein said third movable joint comprises: a third joint spine defining a fifth axis and a sixth axis that is transverse to said fifth axis, wherein said fifth U-shaped bridge is movably and non-removably journaled on said third joint spine for pivotal travel relative thereto about said sixth axis; and a sixth U-shaped bridge movably and non-removably journaled on said third joint spine for pivotal travel relative thereto about said fifth axis.
 3. The universally movable drive shaft of claim 1, wherein said first U-shaped bridge comprises: a first joint cap rotatably supported on a first conical portion of said first joint spine for rotatable travel therearound about said first axis, wherein said first joint cap is spaced from said first conical portion by a first joint space; and a second joint cap rotatably supported on a second conical portion of said first joint spine for rotational travel therearound about said first axis, wherein said second joint cap is spaced from said second conical portion by a second joint space, and wherein said second U-shaped bridge comprises: a first joint ring journaled on a portion of said first joint spine for rotation therearound about said second axis, wherein said first joint ring is retained on said first joint spine by a first flared end of said first joint spine, and wherein said first joint ring is spaced from said portion of said first joint spine by a third joint space; and a second joint ring journaled on another portion of said first joint spine for rotation therearound about said second axis, wherein said second joint ring is spaced from said another portion of said first joint spine by a fourth joint space.
 4. The universally movable drive shaft of claim 1, wherein said universally movable drive shaft is fabricated from a build material that is converted from a first state to a second state by a manufacturing process.
 5. The universally movable drive shaft of claim 4, wherein the manufacturing process comprises a three dimensional printing process.
 6. The universally movable drive shaft of claim 3, wherein said first joint space is configured to contain a first amount of the build material in the first state during formation of said first universally movable drive shaft and exit therefrom after the formation, wherein said second joint space is configured to contain a second amount of the build material in the first state therein during the formation and exit therefrom after the formation, wherein said third joint space is configured to contain a third amount of the build material in the first state during the formation and exit therefrom after the formation, wherein said fourth joint space is configured to contain a fourth amount of the build material in the first state during the formation and exit therefrom after the formation.
 7. A universally movable joint for a shaft of a surgical instrument, wherein said universally movable joint comprises: a joint spine defining a first axis and a second axis that is transverse to said first axis, wherein said joint spine comprises: a first axle segment aligned on said first axis, wherein said first axle segment comprises a flared first end; a second axle segment aligned on said first axis, wherein said second axle segment comprises a flared second end; a third axle segment aligned on said second axis; and a fourth axle segment aligned on said second axis, and wherein said universally movable joint further comprises: a first U-joint pivotally journaled on said joint spine for pivotal travel relative thereto about said first axis, wherein said first U-joint comprises: a first joint ring journaled on said first axle segment for rotation therearound, wherein said first joint ring is retained on said first axle segment by said flared first end; a second joint ring journaled on said second axle segment for rotation therearound, wherein said second joint ring is retained on said second axle segment by said flared second end; and a first bridge extending between said first joint ring and said second joint ring, and wherein said universally movable joint further comprises: a second U-joint pivotally journaled on said joint spine for pivotal travel relative thereto about said second axis, wherein said second U-joint comprises: a third joint cap rotatably journaled on said third axle segment for rotation therearound about said second axis; a fourth joint cap rotatably journaled on said fourth axle segment for rotation therearound about said second axis; and a second bridge extending between said third joint cap and said fourth joint cap, wherein said second bridge retains said third joint cap on said third axle segment and said fourth joint cap on said fourth axle segment.
 8. The universally movable joint of claim 7, wherein said third axle segment terminates in a third conical end, and wherein said fourth axle segment terminates in a fourth conical end.
 9. The universally movable joint of claim 8, wherein said first joint ring comprises a first joint ring inner surface, wherein said first joint ring inner surface is spaced from said first axle segment and said flared first end to define a first joint space, wherein said second joint ring comprises a second joint ring inner surface, wherein said second joint ring inner surface is spaced from said second axle segment and said flared second end to define a second joint space, and wherein said third joint cap comprises: a third axle surface spaced from said third axle segment a third axle joint space; a third conical surface spaced from said third conical end a third tapered joint space that communicates with said third axle joint space to form a third joint space; and a third exit hole through said third joint cap, wherein said third exit hole communicates with said third joint space, and wherein said fourth joint cap comprises: a fourth axle surface spaced from said fourth axle segment a fourth axle joint space; a fourth conical surface spaced from said fourth conical end a fourth tapered joint space that communicates with said fourth axle joint space to form a fourth joint space; and a fourth exit hole through said fourth joint cap, wherein said fourth exit hole communicates with said fourth joint space.
 10. The universally movably joint of claim 7, further comprising: a first joint space between said first ring and said first axle; a second joint space between said second ring and said second axle; a third joint space between said third joint cap and said third axle segment; and a fourth joint space between said fourth joint cap and said fourth axle segment.
 11. The universally movable joint of claim 10, wherein said universally movable joint is fabricated from a build material that is converted from a first state to a second state by a manufacturing process.
 12. The universally movable joint of claim 11, wherein the manufacturing process comprises a three dimensional printing process.
 13. The universally movable joint of claim 12, wherein said first joint space is configured to contain a first amount of the build material in the first state therein during formation of said multi-planar movable joint, wherein said second joint space is configured to contain a second amount of the build material in the first state therein during the formation, wherein said third joint space is configured to contain a third amount of the build material in the first state during the formation, wherein said fourth joint space is configured to contain a fourth amount of the build material in the first state during the formation.
 14. The universally movable joint of claim 13, wherein said first joint space is configured to enable at least some of the first amount of the build material in the first state to exit therefrom after the formation of said universally movable joint, wherein said second joint space is configured to enable at least some of the second amount of the build material in the first state to exit therefrom after the formation, wherein said third joint cap comprises a third exit hole sized to permit at least some of the third amount of the build material in the first state to exit therethrough after the formation, and wherein said fourth joint cap comprises a fourth exit hole sized to permit at least some of the fourth amount of the build material in the first state to exit therethrough after the formation.
 15. The universally movable joint of claim 14, wherein said first joint ring comprises a first joint ring outer surface, wherein said third joint cap comprises a third joint cap outer surface, wherein said fourth joint cap comprises a fourth joint cap outer surface, wherein said first joint ring outer surface is spaced from said third joint cap outer surface a first fillet space, wherein said first joint ring outer surface is spaced from said fourth joint cap surface a second fillet space, wherein said second joint ring comprises a second joint ring outer surface, wherein said second joint ring outer surface is spaced from said third cap outer surface a third fillet space, and wherein said second joint ring outer surface is spaced from said fourth cap outer surface a fourth fillet space.
 16. The universally movable joint of claim 15, wherein said first fillet space is configured to permit at least some other of the third amount of the build material in the first state to exit therethrough after the formation, wherein said second fillet space is configured to permit at least some other of the fourth amount of the build material in the first state to exit therethrough after the formation, and wherein said third fillet space and said fourth fillet space are each configured to permit at least some other of the second amount of the build material in the first state to exit therethrough.
 17. The universally movable joint of claim 7 further comprising a mounting member protruding from one of said first bridge and said second bridge.
 18. The universally movable joint of claim 11, wherein a support material that differs from the build material is contained within said first joint space, said second joint space, said third joint space, and said fourth joint space during the formation.
 19. The universally movable joint of claim 11, wherein said joint spine is formed from a first build material, and wherein said first U-joint and said second U-joint are each formed from a second build material that differs from the first build material.
 20. An articulation joint assembly for facilitating multi-axis articulation of a surgical end effector relative to a shaft assembly of a surgical instrument, wherein the shaft assembly defines a shaft axis, and wherein said articulation joint assembly comprises: a proximal mounting member configured to interface with the shaft assembly; a distal mounting member configured to interface with the surgical end effector; and a plurality of articulation link assemblies attached to said proximal mounting member and said distal mounting member and extending therebetween, wherein each said articulation link assembly comprises: a pair of universally movable joints, wherein each said universally movable joint comprises: a joint spine defining a first axis and a second axis that is transverse to said first axis, wherein said first axis and said second axis are transverse to the shaft axis; a first bridge movably and non-removably journaled on said joint spine for pivotal travel relative thereto about said first axis; a second bridge movably and non-removably journaled on said joint spine for pivotal travel relative thereto about said second axis; and an attachment member protruding from said second bridge, wherein said attachment member is configured to movably affix said universally movable joint to one of said proximal mounting member and said distal mounting member, and wherein said articulation link assembly further comprises an elongate link that protrudes from said first bridge on one of said universally movable joints of said pair of universally movable joints and said first bridge on the other one of said universally movable joints of said pair of universally movable joints and extends therebetween.
 21. The articulation joint assembly of claim 20, wherein said elongate link defines a link axis, wherein said link axis curves around the shaft axis and is not parallel thereto.
 22. The articulation joint assembly of claim 20, wherein said attachment member of one of said universally movable joints is configured to movably affix said one of said universally movable joints to said proximal mounting member such that said one of said universally movable joints is axially movable relative thereto, and wherein said attachment member of the other one of said universally movable joints is configured to movably affix said other one of said universally movable joints to said distal mounting member such that said other one of said universally movable joints is axially movable relative thereto.
 23. The articulation joint assembly of claim 22, wherein each said attachment member defines an attachment member axis that is parallel to the shaft axis.
 24. The articulation joint assembly of claim 20, wherein said second bridge comprises: a first joint cap rotatably supported on a first conical portion of said joint spine for rotatable travel therearound about said first axis, wherein said first joint cap is spaced from said first conical portion by a first joint space; a second joint cap rotatably supported on a second conical portion of said joint spine for rotational travel therearound about said first axis, wherein said second joint cap is spaced from said second conical portion by a second joint space, and wherein said first bridge comprises: a first joint ring journaled on a first axle portion of said joint spine for rotation therearound about said second axis, wherein said first joint ring is spaced from said first axle portion of said joint spine by a third joint space; and a second joint ring journaled on a second axle portion of said joint spine for rotation therearound about said second axis, wherein said second joint ring is spaced from said second axle portion of said joint spine by a fourth joint space.
 25. The articulation joint assembly of claim 24 wherein each said articulation link assembly is fabricated from a build material that is converted from a first state to a second state by a manufacturing process.
 26. The articulation joint assembly of claim 25, wherein the manufacturing process comprises a three dimensional printing process.
 27. The articulation joint assembly of claim 25, wherein said first joint space is configured to contain a first amount of the build material in the first state therein during formation of said articulation link assembly and exit therefrom after the formation, wherein said second joint space is configured to contain a second amount of the build material in the first state therein during the formation and exit therefrom after the formation, wherein said third joint space is configured to contain a third amount of the build material in the first state therein during the formation and exit therefrom after the formation, and wherein said fourth joint space is configured to contain a fourth amount of the build material in the first state therein during the formation and exit therefrom after the formation.
 28. A method comprising: providing a build material that is convertible from a first powdered state to a second solid state; converting a first amount of the build material from the first powdered state to the second solid state to form a first cross-shaped joint spine, wherein the first cross-shaped joint spine defines a first vertical axis and a first horizontal axis that is transverse to the first vertical axis; converting a second amount of the build material from the first powdered state to the second solid state to form a first vertical joint member configured to non-removably pivot on the first cross-shaped joint spine about the first vertical axis; converting a third amount of the build material from the first powdered state to the second solid state to form a first horizontal joint member configured to non-removably pivot on the first cross-shaped joint spine about the first horizontal axis; and evacuating all amounts of the build material remaining in the first powdered state from between the first cross-shaped joint spine, the vertical joint member and the horizontal joint member.
 29. The method of claim 28, wherein said converting a first amount of the build material from the first powdered state to the second solid state further comprises forming a second cross-shaped joint spine, wherein the second cross-shaped joint spine defines a second vertical axis and a second horizontal axis that is transverse to the second vertical axis, wherein said converting a second amount of the build material from the first powdered state to the second solid state to form a first vertical joint member further comprises forming a second vertical joint member configured to non-removably pivot on the second cross-shaped joint spine about the second vertical axis, and wherein said converting a third amount of the build material from the first powdered state to the second solid state to form a first horizontal joint member further comprises forming a second horizontal joint member protruding from the first vertical joint member and configured to non-removably pivot on the second cross-shaped joint spine about the second horizontal axis.
 30. The method of claim 29, wherein said converting a first amount of the build material from the first powdered state to the second solid state further comprises forming a third cross-shaped joint spine, wherein the third cross-shaped joint spine defines a third vertical axis and a third horizontal axis that is transverse to the third vertical axis, wherein said converting a second amount of the build material from the first powdered state to the second solid state to form a first vertical joint member further comprises forming a third vertical joint member configured to non-removably pivot on the third cross-shaped joint spine about the third vertical axis, and wherein said converting a third amount of the build material from the first powdered state to the second solid state to form a first horizontal joint member further comprises forming a third horizontal joint member protruding from the second vertical joint member and configured to non-removably pivot on the third cross-shaped joint spine about the third horizontal axis. 